Let's get started...

Materials and Tools

Materials needed for the Window Solar Panel:

1. Screen frame Material
2. Screen framing Corners
3. Aluminum flashing
4. Black Cinefoil
5. Heat resistant aluminum tape
6. Window treatment film (comes with double sided tape)
7. Suction cups
8. Eye screws
9. #10 eye screws
10. Optional two soffit vents (not shown)

Basic tools needed:

1. Tin snips or heavy duty scissors
2. Needle nose pliers
3. Measuring tape
4. Marking pen
5. Utility Knife

— Optional Tool Upgrades—
For easier and more accurate cutting and to upgrade your panel,
these additional tools and parts are needed:

1. Hack saw for better cuts or even better, a power miter saw
2. Small drill with 1/8 inch bit
3. Riveting tool with 1/8 inch rivets 1/4 inch long
4. Eye bolt driving tip
5. Needle nose pliers
6. Straight edge (for cutting)

And of course, a hair dryer... if you are one of those super-observant people... you will see, I don't need the hair dryer

Building The Frames

So that your cuts make for a square solar panel... tape together four lengths of screen frame.

After cutting to size, insert the corners.

Completed Frames.

The back of the panel

Use your hair dryer to heat-up the glue holding the sticker on. (makes removal easy of any stickers)

Measure the roll of roof flashing to your desired length.

After marking, position a straight edge and tape it down.
(Yep, a utility knife will cut flashing with a few passes)
 

Carefully cut the flashing.

Mark both ends of your cut flashing for the vents you desire to use.

More marking.
 

Use a deep throat paper punch to get enough reach.
I remove the piece catcher to see though the hole to help align the punch over the hole.

Repeat.

Finished with the back of the panel...

Preparing the "solar" foil

Remove foil from protective box.
 

Use the aluminum flashing you already cut to size for sizing the foil.

Use utility knife to cut foil.

Also cut to length.

Now roll the foil up for later use.

Apply Flashing to First Frame

Align the flashing to the frame.

Start the taping process for the flashing.

Tape each corner as shown.

Apply tape to the centers of each end and side.

Position flutes to make sure a clear channel is maintained through the heating chamber.
Although this is not a necessary step it helps and prevents waste.
Flutes are just the cut off pieces (left over's) from the pieces cut to size.

Tape the flutes down.

Drill two to three holes in each piece.
 

Turn panel over and start riveting.
 

After all rivets have been inserted, turn panel over again to prepare for the foil.

Applying the foil, the second frame and prepare for film

Align the foil to the opposite side of the first panel with the flashing back.

Center the foil and tape the center of one end.

Then center the other end and start tapping the rest of the panel.

Tape the corners first.

Then tape the sides.

Place the second frame on top of the foil side and repeat the aluminum taping process.

Start taping the perimeter of the second frame with the supplied double stick tape from
the window film kit.

After all pieces of the frame are taped, peel back the protective layers of tape about an
inch or so then set the panel aside.

Applying the window film and aluminum trim tape

Tape the film down on a floor or table to have it laying flat.

Tape, pulling each corner until you get the rolls out of the film...
the wrinkles will be taken care of with the hair dryer.

Now place the panel down with the double stick tape facing up and remove the tapes
backing paper.

Flip the panel over... As you can see, this process makes it easy to place the film on the
tape with "NO" headaches.

Press down on all corners and around the perimeter to make sure the tape grabs the film.

Cut around the perimeter to remove excess film.

Remove the excess film and flip the panel over.

Pre-measure and cut the aluminum tape for all sides.

Peel back the tape backing a couple inches.

Align the tape and press the exposed sticky side of tape to the film.

Align the non-exposed side of the tape and start peeling off the backing.

Now press the tape down gently to give you a nice clean edge.

As you apply the aluminum tape, flip the panel up to wrap the tape around the back
finishing off this process

 Now for some fun (at least I think so).
Use your hair dryer to shrink the film finishing off the panel.

Final Step - Apply the Hangers

Drill each corner with a 3/32 bit for starter holes.

Start the eye hooks by hand.

Carefully run the eye hooks down with a special driver bit. If you use any other tool
be careful to not scratch the film.

As you can see, the eye hooks accept the window suction cups well.

Success... The finished panel !!!

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