Hi Jeff, I've been collecting parts for my panel too!! I'm using one of those sliding glass shower doors, the glass may not being the best for UV transmission, but it is tempered. For the frame I'm using an old aluminum storm door. I think the hardest part in making the panel is soldering the tabs onto the cells, without breaking them!!! I buy 40 of the 6" round 3 watt cells. I still have to buy the backing sheet from
www.livingoffthegrid.com and build a makeshift vacuum press for applying the backing to the panel.
Hi South Easter, The lamination of the panels is one of the most important parts of the whole process!! Any air or moisture allowed to come in contact with the solder joints and tabs will cause oxidation over time, which is the cause of most panel failures. So.. the better the seal, the longer the panel will last. I think I'll be doing a small panel or two, before I attempt my 120 watt panel, just to get the method down. I know that once you apply heat to those sheets, it's a done deal!!
Blessings, Snow Crow