How to Make your Own Portable Solar Generator of 1000Wh Power and 100W Solar Panel for Under $400

Making own DIY solar generator is not a big job. It is a simple process and inexpensive too compared to buying new one. Yes, it costs a fortune to buy a good portable solar generator. But if you know the basics of solar technology, it is an easy task to set up a solar generator DIY in a matter of time.

In fact, setting up a DIY portable solar generator is all about assembling components. You won’treally create anything new here. You just put together solar generator parts and compoments that are readily available on market.

Well, there is actually no a specific form for a portable solar generator. Anything that wires together basic components like solar module, battery pack, inverter and charge controller is roughly a solar generator. Then, what makes a full-fledged, branded solar generator different is mainly its look and design. Well, you can also bundle up your DIY solar generator parts in a well-contained box or case to make it portable and friendly for outings.

DIY Solar Generator – 1000Wh Solar Generator

What all required for a DIY solar generator are plenty available on market. Well, for this solar generator DIY guide, we take real parts from Amazon.com as exmaples. That is, you can quickly get an idea on each part needed and buy it via the given affiliate link. Anyway, before moving into the guide let us have a look at the list of key components. We got a design diagram to give you an exact picture of the assembly of this 1000Wh solar generator.

1) Portable Solar Panel Unit – 100W
2) Solar Charge Controller – 30 Amps
3) Lead Acid Battery – 35Ah
4) Power Inverter – 1000Wh
5) Voltmeter
6) Wires and Cables
7) A Solid Case

Here we have taken Renogy’s one of top selling 100W 12V polycrystalline solar starter kit to explain how a DIY solar generator is put together. Well, the solar panel kit bundle contains a 100 watts solar panel, 30A PWM charge controller, wires and cables and mounting brackets. We have made a random pick of a power inverter and battery that can work nicely with the kit. Anyway, get familiar with each component and its specs below.

Portable Solar Panel Unit 

Needless to say, solar panel is the vital part of a DIY solar generator. You get portable solar units mainly in two variants; folding and flat glass panels. As can see, a folding solar panel is easy and hassle-free for moving. Its mounting is also simple. Coming to the conventional flat solar unit, its moving would be rather tough, but you could erect it on aluminum panel or mounting brackets to grab sunlight.

Moreover, you can also see ultra-thin foldable and curved solar panels out there, but they are pretty expensive when compared to traditional panels. But mounting a curved solar panel is amazingly awesome, thanks to its curvature to fit any irregular surface. Whatever, as a typical example, here we have taken Renogy’s 100 watts polycrystalline solar unit that can charge up 12V batteries from sunlight.

Well, this unit of solar panel guarantees you 14.6% solar conversation, which is good enough for a DIY solar generator. Fine, with that power it can produce 500 watts hours of energy on an average a day under bright sun. Luckily, the Renogy kit comes with all required mounting brackets so that you can easily put up the panel anywhere. And for taking it in your trips, you may require a carrying case, however.

Solar Charge Controller – Included in the Kit

Solar charge controller is indeed an essential part of a solar generator. It is what controls the rate at which solar energy is pumped into the battery. This way it prevents overcharging. Absolutely, it is a security feature that stabilizes power flow from the largely unstable solar source and increases lifespan of battery.

Here, as you know, the Renogy solar kit packs Renogy’s Wanderer 30A PWM solar charge controller. It is a tiny device that you can screw up to your DIY solar generator case or wall if you plan to use the system stationary. Well, this charge controller supports future expansion of the system up to a maximum of 400 watts.

Battery or Power Pack

Simply, a battery is used to store the harvested solar energy. Battery is indeed the heftiest part of the system. You can mount the battery with enough air vents in your DIY solar generator case. Variety of battery types is available on market and you can pick one based on the compatibility with the charge controller. The Renogy Wanderer is compatible only to sealed lead acid and flooded batteries.

Hence, we have picked Chrome Battery’s 12V 35Ah sealed lead acid battery for this solar generator DIY. Well, with the bundled solar panel, you can charge the battery in around 2 hours, depending on the intensity of sun, of course. This lead acid battery weighs at 23.5 pounds and has a size of 7.7 x 5.1 x 6.5 inches.

Power Inverter
Power inverter is another essential part of the solar generator. As you know, the function it does is to convert DC in the battery to AC so that your appliances and gadgets can work on it. Typically, inverter comes with universal AC sockets to charge large appliances. You can also get models with USB ports as well. Otherwise, you can use a car cigarette lighter to power up gadgets less than 150W.

Anyways, here we have taken BestTek’s 1000W inverter with dual AC outlets to convert 12V DC to 120V AC. That is why it becomes a 1000Wh DIY solar generator. The unit is, in fact, made rugged and compact for rough outdoor use. It comes with battery clamps and a cigarette lighter adapter, by the way.

Voltmeter

Voltmeter is not a very vital part of a DIY solar generator. Its function is to let you read the flow of current from photovoltaic cells. Well, based on the data, you can replace the solar unit to somewhere with better sunlight and collect more power. A voltmeter can go anywhere you have 12 volts DC. The included voltmeter offers a measuring range of 7.5V – 20V. And its size goes at 76 x 39 inches.

Wires and Cables (Included in the Kit)

When it comes to wires and cables for a DIY solar generator, you need to take good care. You need to use correct size cables to prevent loss of energy and safeguard the system from damages. For exact wire size required for a solar generator system, just go here. Anyway, the Renogy solar kit bundles 20ft 10AWG MC4 adaptor kit and 8ft 10AWG tray cable. Plus, the included inverter comes with battery clamps.

Carrying Case

Once you have all the above components, you can find a carrying case to set them up neatly. Make sure you buy a case that can endure rough outdoor conditions and a solid handle to take it along. You can fix each item of the DIY solar generator parts, except solar panel in it to make it a cool portable machine.

DIY Solar Generator Wiring Diagram

Final Words

Overall, it costs below $400 to set up this DIY solar generator. Yes, to buy as much as powerful solar generator you will have to spend around $1000, for sure. But thing is that it is not a compact and well-contained system. As per your talent to put them together, it will be doing better, however. This solution is, anyway, great for stationery and emergency use, but for camping or outdoor use, it won’t be much reliable as it not integrated.