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Offline ryangus

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Shattered Solar Panel
« on: January 11, 2012, 05:54:14 PM »
A mate just rang me very upset about the fact he's shattered one of his panels, due to a mistaken drill into the side of the glass when attaching a hinge!!  :o

He heard a loud crack, and the glass shattered into bits about the size of a 5c piece, but apparently the top laminate(?) is still intact - he can't  feel any of the cracks on the surface.

Before he throws it away, a couple of questions.

Will it still work provided it's still intact?  I imagine it will be OK in a stationary environment, but no good for travelling with.

Is there any way he can repair it?  Economically?

Needless to say, he's not a happy camper right now!  >:(
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Offline GeoffA

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Re: Shattered Solar Panel
« Reply #1 on: January 11, 2012, 06:22:28 PM »
DON'T THROW IT AWAY!!!!

I did the same thing............ ::) ..............and mine still works OK.

I got some 6mm UV resistant polycarbonate acrylic cut to suit the panel. A mate in the silicones game had some liquid silicone (sets to a clear gel) that we poured onto the panel surface, then laid the sheet over the top. It's been fine for a while, but the shattered glass caused the panel crown a bit and the poly acrylic is lifting around the edges. 6mm poly acrylic is too thick if the panel has crowned. Still works OK, but it needs re-doing........

I've added a couple of 25mmx25mm aluminium SHS braces to the back of the panel, and I'm going to Sikaflex (or similar) the panel down to the braces to get rid of the crowning. Once it's flat (or flatter than it is), I'll re-do the silicone. It should stay good.

If I was to do it again from scratch, I'd fit the braces to the back of the panel to get it flat, then use some 3mm thick UV resistant polycarbonate acrylic over the damaged surface of the panel. A bead of silicione sealant/adhesive around the edges of the panel should keep the polycarbonate acrylic in place, protect the hands from little bits of glass, and keep the weather out.........

 :cheers:
Geoff

edited 'cos I sometimes have a crap memory...........acrylic/polycarbonate..........same, same???..... ::)
« Last Edit: January 13, 2012, 05:40:21 PM by GeoffA »
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Offline ryangus

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Re: Shattered Solar Panel
« Reply #2 on: January 11, 2012, 06:48:54 PM »
Agreed Geoff.  I've done some research - my mates a luddite :) - and all seem to say they've noticed no drop in performance.  Where would he find the 3mm polycarbonate? (that will be his next question no doubt!)
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Offline 98jack

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Re: Shattered Solar Panel
« Reply #3 on: January 11, 2012, 06:55:35 PM »
ryangus,
    whereabouts are you located?

 :cheers:
Glenn
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Offline ryangus

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Re: Shattered Solar Panel
« Reply #4 on: January 11, 2012, 07:00:27 PM »
I'm from Brisbane, but he's on the Mornington Peninsula in Victoria.
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Offline 98jack

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Re: Shattered Solar Panel
« Reply #5 on: January 11, 2012, 07:12:13 PM »
ryangus,
        I know when i used to work for CBC Bearings in Sydney we had access to polycarbonate sheeting, maybe your mate could try his local CBC, otherwise if he searches for perspex suppliers in Vic as most perspex suppliers will also be able to supply polycarb.

 :cheers:
Glenn
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Offline 2003gxl

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Re: Shattered Solar Panel
« Reply #6 on: January 11, 2012, 08:00:54 PM »
This has recently happened with one side of my folding panel, someone dropped the iron onto it  :'(, and I was going to get one side replaced. I used it over xmas and it still performed great. The only problem is the shattered panel flexes so I am making up a panel to go on the back out of 5mm ply so it doesnt flex. I will be keeping a eye on this thread.
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Offline GeoffA

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Re: Shattered Solar Panel
« Reply #7 on: January 11, 2012, 08:04:59 PM »
Quote from: ryangus on January 11, 2012, 06:48:54 PM
Agreed Geoff.  I've done some research - my mates a luddite :) - and all seem to say they've noticed no drop in performance.  Where would he find the 3mm polycarbonate? (that will be his next question no doubt!)

I'm in Melbourne, and got mine from a place in Dandenong. Can't remember their name, but I just Googled.....
UV resistant is important. Scratch resistant stuff is too expensive. Mine's holding up well.

With the glass shattered, the panel gets a bit soft and will need support. The alloy SHS braces will sort that....
« Last Edit: January 13, 2012, 05:33:13 PM by GeoffA »
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Offline ryangus

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Re: Shattered Solar Panel
« Reply #8 on: January 11, 2012, 08:13:30 PM »
Quote from: GeoffA on January 11, 2012, 08:04:59 PM
I'm in Melbourne, and got mine from a place in Dandenong. Can't remember their name, but I just Googled.....
UV resistant is important. Scratch resistant poly is too expensive. Mine's holding up well.

With the glass shattered, the panel gets a bit soft and will need support. The alloy SHS braces will sort that....
Thanks.  Can you remembered what you paid?  I might be buying this panel off him (he's a perfectionist), and would like to know what I'm up for.

Also, can't quite picture the allow braces - any photos or diagrams etc?
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Offline GeoffA

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Re: Shattered Solar Panel
« Reply #9 on: January 11, 2012, 09:20:27 PM »
Quote from: ryangus on January 11, 2012, 08:13:30 PM
Thanks.  Can you remembered what you paid?  I might be buying this panel off him (he's a perfectionist), and would like to know what I'm up for.

Also, can't quite picture the allow braces - any photos or diagrams etc?

Mine's a 100 watt panel, and it's about 1200 x 540. I think I paid about $50 for the 6mm poly, cut to size. 3mm would be less.

The braces are just 2x1180mm lengths of 25mm square tube, equally spaced. They fit very snugly in the back of the panel, and are pop rivetted to the panel frame at each end. I ran mine from top to bottom to clear the support leg, but they would be better if they ran across the panel. I haven't stuck the panel to them yet. Will get to that eventually........

Pics attached.........(hopefully).........

 :cheers:
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Offline ryangus

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Re: Shattered Solar Panel
« Reply #10 on: January 11, 2012, 09:36:32 PM »
Thanks mate - might buy it off him methinks if it's at the right price ;)
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Offline McGirr

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Re: Shattered Solar Panel
« Reply #11 on: January 11, 2012, 10:06:48 PM »
I would say to him mate it's not worth fixing and offer to take it off his hands ... ha ha

Mark
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Offline ryangus

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Re: Shattered Solar Panel
« Reply #12 on: January 13, 2012, 10:25:22 AM »
Thermotec in Dandenong want $100 for 3mm (if they had an offcut which they don't)!  Can't remember where you got yours can you Geoff?
« Last Edit: January 13, 2012, 10:31:33 AM by ryangus »
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Offline GeoffA

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Re: Shattered Solar Panel
« Reply #13 on: January 13, 2012, 04:35:29 PM »
Quote from: ryangus on January 13, 2012, 10:25:22 AM
Thermotec in Dandenong want $100 for 3mm (if they had an offcut which they don't)!  Can't remember where you got yours can you Geoff?


You're in luck!!!! I kept a business card.......... ;D

AB Plastics
3 Carl Court
Hallam VIC 3803
(03) 9796 4030

http://www.abplastics.com.au

Dandenong......Hallam........same, same..........

They had a rack with offcuts, and they cut mine while I waited.

Friendly service, and good advice.
Maybe try asking for acrylic sheet instead of polycarbonate (I think I should have typed "acrylic" instead of "polycarbonate" in previous posts ::) Apologies for any confusion I've caused.......). Make sure it's UV stabilised. Talk to them to confirm.

They said at the time that they also do quite a few rear window protectors for the 4x4/camping crowd.

They were the best on price when I was ringing around. Some were quite $$$$.
(I hope my recollection of the price is somewhere in the ball park........... ::))

 :cheers:
Geoff

« Last Edit: January 13, 2012, 05:46:28 PM by GeoffA »
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Offline Alloy C/T

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Re: Shattered Solar Panel
« Reply #14 on: January 13, 2012, 05:18:04 PM »
2003gxl , you might find that your shattered panel WILL lose performance when you glue a sheet of timber to the back , less heat dissipation will be the result equaling less performance,, yes panels get hot BUT the rear of a panel should never be restricted from air flow ,,,
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Offline ryangus

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Re: Shattered Solar Panel
« Reply #15 on: January 13, 2012, 08:36:18 PM »
Thanks Geoff,  I'll call them next week.

Sent from the dodgy keyboard on my phone via Tapatalk
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Offline itchvet

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Re: Shattered Solar Panel
« Reply #16 on: January 20, 2012, 08:04:02 PM »
Quote from: ryangus on January 11, 2012, 05:54:14 PM
A mate just rang me very upset about the fact he's shattered one of his panels, due to a mistaken drill into the side of the glass when attaching a hinge!!  :o

He heard a loud crack, and the glass shattered into bits about the size of a 5c piece, but apparently the top laminate(?) is still intact - he can't  feel any of the cracks on the surface.

Before he throws it away, a couple of questions.

Will it still work provided it's still intact?  I imagine it will be OK in a stationary environment, but no good for travelling with.

Is there any way he can repair it?  Economically?

Needless to say, he's not a happy camper right now!  >:(

See, that's why the old UNISOLAR panels are the best.
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Offline Mandrake

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Re: Shattered Solar Panel
« Reply #17 on: January 21, 2012, 03:07:56 AM »
Send a pm to Geoffa on here. He did the same thing and fixed it
 Cheers
Steve

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Offline itchvet

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Re: Shattered Solar Panel
« Reply #18 on: November 03, 2015, 10:41:16 PM »
This is good example of why to avoid glass solar panels for camping, people.
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Offline GeoffA

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Re: Shattered Solar Panel
« Reply #19 on: November 04, 2015, 05:02:55 AM »
Quote from: itchvet on November 03, 2015, 10:41:16 PM
This is good example of why to avoid glass solar panels for camping, people.

Ummmm.......

These didn't break when camping......surprisingly few do.....
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Offline speewa158

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Re: Shattered Solar Panel
« Reply #20 on: November 04, 2015, 05:40:02 AM »
Quote from: GeoffA on November 04, 2015, 05:02:55 AM
Ummmm.......

These didn't break when camping......surprisingly few do.....
Usually it happens in the relative safety of  " The Shed "  not far from the Engal       ::)    :cheers:
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Offline plusnq

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Re: Shattered Solar Panel
« Reply #21 on: November 04, 2015, 05:59:26 AM »
Quote from: speewa158 on November 04, 2015, 05:40:02 AM
Usually it happens in the relative safety of  " The Shed "  not far from the Engal       ::)    :cheers:

Very suspicious
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Offline jetcrew

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Re: Shattered Solar Panel
« Reply #22 on: November 04, 2015, 09:28:29 AM »
The panel is worth nothing .. When you price up what you spend to repair it and then only get 40% output or thereabouts plus the size and weight you will see that the actual panel has no value .. If your in Bne and want to buy smashed panels I could have sent you a few lol  :D just threw out a few

A smashed 100w panel might do 3 amps cost to repair is $60-$80 then you lug around a 7kg panel for 3 amps .. You can buy a 60w panel for not much more and it's half the weight and size .

If like Geoff you already own the panel then all good but to buy it and freight it then repair it .. Not viable $$$ wise imho

Jet ;D
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Offline GeoffA

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Re: Shattered Solar Panel
« Reply #23 on: November 04, 2015, 11:04:14 AM »
Quote from: jetcrew on November 04, 2015, 09:28:29 AM
....... to buy it and freight it then repair it .. Not viable $$$ wise imho

Agree with you there Theo.

This is a very old thread........
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Offline slydar

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Re: Shattered Solar Panel
« Reply #24 on: November 04, 2015, 04:40:54 PM »
weren't they all saying they've not seen any drop in performance? not that I want to find out

and I do hate the weight of the glass ones - wish the 'flexible' ones weren't so expensive...
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