DIY Solar System Build Guide

Author

Brad Brown

About the Author

Brad Brown is a Silicon valley computer programmer that lives in California.

Last Updated

6/28/2026

Status

This document is currently in development and still being updated until further notice here.

Disclaimer

General

Although, I try to make this document accurate, I'm not responsible or liable for any errors. I'm not responsible or liable for any problems or damages that you might encounter if you use any information from this document. In addition, any work you do is done at your own risk.

Warning High Voltage

You can encounter high voltages that can be deadly so any work you do is done at your own risk. This document is not intended to teach you how to work with high voltages.

Overview

The DIY Off-grid Solar System Build Guide shows how to build a DIY off-grid solar system for use in the United States paying particular attention to saving money.

The DIY Off-grid Solar System Build Guide shows solar system components.

I provide exact parts and prices at the time from one vender as an example of what might be good for use in a solar system so that you can more easily see what type of parts to buy.

None of these links are affiliate links.

All of these parts are picked by me and are parts that I might consider buying myself but aren't tested or being recommended by me. None of these parts or vendors are being recommended by me, nor am I claiming the price is the lowest. Please do your own research when selecting parts and where to buy them and at what price.

Prices are subject to change. Prices can change every day up or down in the short term so I put the date that I saw the price. In general prices for solar have been getting cheaper in the long run but things like tariffs could change that.

Solar System Component Parts

This is a parts list of Solar System Component Parts. This covers anything from solar generators to individual components. Basically this section covers all parts except wiring and hardware.

These parts are used in the Solar System Component Configurations below.

Test Equipment

HBN Watt Meter Plug with Backlight, Plug-in Socket Power Meter Electricity Usage Monitor Consumption Home Electrical Energy Monitor, Voltage Amps Wattage Electricity Usage Tester, 9 Display Modes ($9.99 11/12/2025)

Electrician High Voltage Gloves

Electrician Gloves Voltage Resistance Electrician High Voltage Gloves Insulation Work Gloves Flame Retardant & Rubber Non-Slip Grip for Electrical Work (Black and White, 400V-1PC) ($9.85 11/12/2025)

Solar Generators

2000W

3400W

EF ECOFLOW Portable Power Station DELTA 3 Max, 2048Wh LiFePO4 Battery, Solar Generator (Solar Panel Optional), 3400W X-Boost Output, Ultra-Fast 0-80% Charging in 1.13 Hr, Home Backup & RV Camping ($799.00 10/17/2025)

3600W

PECRON E3600LFP Portable Power Station 3600W 3072Wh ($999.00 10/30/2025)
AFERIY P310 Portable Power Station with Expandable Capacity 3600W 3840Wh ($1,099.00 10/30/2025)
EF ECOFLOW Portable Power Station 3600Wh DELTA Pro, 120V AC Outlets x 5, 3600W, 2.7H Fast Charge, Lifepo4 Power Station, Solar Generator for Home Use, Power Outage, Camping, RV, Emergencies ($1,399.99 10/17/2025)

Solar System Kits

100W panels

100 Watt 12V Solar Panel Kit with 30A PWM Charger Controller, 10AWG Solar Cable & Tray Cable, Z Brackets for RV, Battery, Boat, Camper, Cabin, Off-Grid System (100W Solar Panel Kit) ($64.99 10/17/2025)

200W panels

200W bifacial panels

Solar Panel Kit 200W Solar Panels 30A PWM Solar Charge Controller A+ Cell Solar Panel Cables Connectors Brackets for RV Boats Battery Marine Home Outdoor Off-Grid System ($124.99 10/17/2025)

200W panels 12V 100Ah

ECO-WORTHY 200 Watt 12V Complete Solar Panel Starter Kit for RV Off Grid with Battery and Inverter: 2pcs 100W Solar Panel + 30A Charge Controller + 100Ah Lithium Battery + Premium Solar Inverter ($459.98 10/20/2025)

800W DIY grid-tie

The manufacturer says this is legal in all 50 states but it is a good idea to check with your local power company before buying it to make sure.

Note this requires installing a sensor in your breaker panel which is not what I would call plug and play. If you don't feel comfortable installing the sensor in a breaker panel you will need to hire an electrician to do that part for you.

800 Watt CraftStrom Plug and Play Smart Solar ($2,031.50 10/3/2025) YouTube

Solar Panels Rigid Mono-facial

100W

200W

200 Watt Solar Panel 18BB, 25% High Efficiency, N-Type 12V 200W Solar Panel, Monocrystalline PV Modules, for Rooftop, RV, Farm, Trailer, Marine, Home Off-Grid System ($119.99 - $10 coupon = $110.99 10/26/2025)

400W

DOKIO 400W Monocrystalline Solar Panel 12/24V, 3 m MC4 Cable for Yard/Garden - Shed/Patio/Greenhouse Power, Off-Grid Battery Charging, 12V Parallel Wiring Recommended, Easy to Route ($238.99 10/27/2025)

Solar Panels Rigid Bifacial

100W

HQST Bifacial 100 Watt 12V Solar Panel, 9BB Monocrystalline Solar Panels with 25% High Efficiency Module PV Power for Battery Charging Boat, Caravan and Other Off Grid Applications ($49.99 10/18/2025)

200W

400W

This shows solar panels generally cost a lot more when ordering in small quantities on Amazon because of the high cost of shipping. A single 400 watt solar panel on Amazon costs $279 for one but you can order ten 400 watt solar panels for $126.00 each if ordering 10 at a time from Signature Solar but you have to pay shipping of around $366 which is about $170 per panel with tax and shipping.

Is Amazon Ripping You Off?

JJN Bifacial 400 Watt Solar Panel, N-Type 16BB 400W Solar Panels, 25% High Efficiency Monocrystalline Solar Module for 12V/24V/48V PV System for Homes Rooftop Farm RV and Off-Grid Applications ($279.98 10/23/2025)
Hyperion By Runergy 400w Bifacial Solar Panel (Black) | Up to 500W with Bifacial Gain (10 × $126.00 = $1,222.20 10/26/2025) (Minimum purchase 10.) (Shipping cost varies but $366 is one example.)

445W

2PCS 445 Watt Solar Panels 12/24Volt Bifacial Solar Panel kit High Efficiency for RooftopPortable Power Station Farm Yacht and Other OffGrid Applications Total 890W ($449.00 11/18/2025)

Solar Panels Flexible Mono-facial

None

Solar Panels Portable

100W

DOKIO 110w 18v Portable Foldable Solar Panel Kit (21x28inch, 5.9lb),Solar Controller 2 USB Output to Charge 12v Batteries/Power Station (AGM, Lifepo4) Rv Camping Trailer Emergency Power ($65.42 10/3/2025)

Charge Controllers

PWM 30A

PWM 40A-100A

MPPT 20A

MPPT 30A

MPPT 40A

MPPT 50A

50 Amp MPPT Solar Charge Controller, 12/24V Auto Detection, Commercial Grade, Multi-Charging Modes with Reverse Polarity Protection for Home and RV Use ($43.69 11/16/2025)

MPPT 60A

Batteries 12V

Warning batteries on Amazon often do not have free shipping so always check how much the delivery charge is to find the total price.

12V 7Ah

12V 7Ah Lithium LiFePO4 Battery - Direct Replacement for 6FM7 SLA Battery, 2000+ Cycles, Lightweight, Built-in BMS, Ideal for Solar Systems, Ride-on Toys, and Home Alarms ($15.99 11/9/2025)

12V 15Ah

12V 100Ah (Low Temperature Protection)

12V 100Ah (Low Temperature Protection, Bluetooth)

Batteries 24V

Warning batteries on Amazon often do not have free shipping so always check how much the delivery charge is to find the total price.

24V 50Ah (No Low Temperature Protection)

25.6V 50Ah LiFePO4 Battery, Built with 100A BMS, Max. 2560W Power, BCI Group 24 Size Lithium Battery, Support in 2 Series/4 Parallel, Perfect for Trolling Motor, RV, Camping, Solar Home ($229.99 - $20 coupon = $209.99 1/5/2025)

Batteries 48V

Warning batteries on Amazon often do not have free shipping so always check how much the delivery charge is to find the total price.

48V 25Ah (No Low Temperature Protection)

48V 100Ah (No Low Temperature Protection, Bluetooth)

ECO-WORTHY 48V 100Ah LiFePO4 Lithium Battery, 5.12kWh Capacity, Server Rack Battery with Bluetooth, 6000 Cycles, 3U Chassis, Perfect for Off-Grid, Solar, Backup Power ($999.99 - $110 coupon = $889.99 2/17/2025) YouTube

Inverters 12V

400W

400W Power Inverters for Vehicles DC 12V to 110V AC Car Truck with Dual AC Outlets USB with 2 Type-C,12 Volt Inverter Car Cigarette Lighter Battery Inverter ($16.99 10/19/2025)

500W

WZRELB 500W Pure Sine Wave Inverter 12V DC to 110V 120V AC Power Converter with LED Display, Off-Grid Portable Power Inverter with 2 AC Outlets for Home, RV, Truck, Camping ($29.48 10/22/2025)

600W

WZRELB 600W Pure Sine Wave Inverter 12V DC to 110V 120V AC Power Converter with LED Display, Off-Grid Portable Power Inverter with 2 AC Outlets for Home, RV, Truck, Camping ($41.03 10/19/2025)

800W

1000W

1000 Watt Pure Sine Wave Power Inverter 12V DC 110V/120V AC with LED Screen Display 2AC Outlets, 5V 2.4A USB Port Power Converter for Car, Truck, Home, Trip ($49.99 10/22/2025)
WZRELB 1000W Pure Sine Wave Inverter 12V DC to 110V 120V AC Power Converter with LED Display, Off-Grid Portable Power Inverter with 2 AC Outlets for Home, RV, Truck, Camping ($76.58 10/22/2025)
1280W Pure Sine Wave Power Inverter - 3600W Surge, Game-Changing Design | 12V to 120V AC Converter for Home, RV, Camping, Off-Grid & Outdoor Adventures ($119.00 - $35.00 coupon = $84.00 11/8/2025)

1800W (120V x 15A Outlet)

2000W

2400W (120V x 20A Outlet)

3000W

Inverters 24V

3000W

POWLAND 3000W Solar Inverter, Pure sine Wave Inverter, 24V to 110V/120V, Built-in 60A MPPT Controller, Suitable for Homes, RVs, and can be Used with Lithium Lead-Acid Gel Battery Off-Grid Systems ($349.99 1/8/2025)

3600W Hybrid (Inverter can run without battery)

Xijia 3600VA MPPT Hybrid Inverter 3600W Pure Sine Wave Power Inverter with 120A MPPT Solar Charger DC24V to AC110V 60HZ Solar Converter for Home Use，Off-Grid Cabin,Max PV 4200W DC60-500V ($303.00 12/2/2025)

Inverters 48V

2000W

2000W Power Inverter 48V DC to 110V AC 60HZ Pure Sine Wave Converter with LED Display for Off Grid Solar System ($159.00 - $20 coupon = $139.00 1/5/2025)

2500W

New 48V 2500 Watts Pure Sine Wave Inverter, 48V DC to 110V AC Power Inverter with 4 AC Outlets, USB Port, Type-C Port for Truck, Vehicle, Power Outage, Remote Control with LCD Screen ($219.99 - $20 coupon = $199.99 1/5/2025)

4000W

WZRELB 4000W 48V Pure Sine Wave Inverter,48 Volt DC to AC 120V 240V Split Phase Power Inverter,8KW Surge,5 AC Outlets,AC Hardwire Terminal,15ft LCD Remote Panel ($473.27 10/19/2025)

Inverter Pre-charge Resistor

None ($0.00 1/22/2025)

AC Battery Charger

Battery Box

Fireproof

Box

12V

12V, Charge Controller, Inverter

Licitti 1000W AC Battery Box ($168.00 + $55.00 Shipping: = $223.00 11/13/2024)

Power Distribution Box

Low Energy Appliances

Refrigerator

Frestec Mini Fridge with Freezer 3.2 Cu.Ft. 2 Door Refrigerator and Freezer Small Fridge for Bedroom Home Office Dorm, Small Drink Chiller, 37 dB Low Noise, Stainless Steel ($139.99 11-6-2025) (320 kilowatt hours per year.)

Tip:

When shopping for refrigerators check the kWh/year because not all small refrigerators are efficient. As an example, I have the 18 cu. ft. refrigerator below that uses 411 kWh/year which is not Energy Star certified. However, below I show a 3.4 cu. ft. that uses 549 kWh/year and is Energy Star certified but uses more energy than my full size refrigerator so don't assume just because it is small it uses less energy.

Whirlpool 18.2 cu. ft. Top Freezer Refrigerator in White (411 kilowatt hours per year)
3.5 Cu.Ft Compact Refrigerator Mini Fridge with Freezer,7 Level Adjustable Thermostat Removable Shelves Small Refrigerator for Office Dorm Apartment Black,(KB02 FLS-80-BLACK) ($79.99 11-6-2025) (549 kilowatt hours per year)

Clothes washer

COSTWAY Portable Washing Machine, Twin Tub 26lbs Capacity Laundry Washer, 18lbs Washer and 8lbs Spinner Combo with Timer Knobs, Built-in Drain Pump, Compact Washer for Home Dorm Apartment, Blue+White $159.99

Solar System Wiring Parts

This is a parts list of Solar System Wiring Parts. This covers anything from wires to mounting hardware.

These parts are used in the Solar System Component Configurations below.

Mounting Kit

Switch

Transfer Switch

Nature's Generator Transfer Switch 6 Circuits 120V 30A Non-Automatic UL Power Transfer Kit(Indoor) ($269.99 10/31/2025) YouTube

Master Switch

Ampper Battery Switch, 12-48 V Battery Power Cut Master Switch Disconnect Isolator for Car, Vehicle, RV and Boat (On/Off) ($11.99 1/3/2025)

Isolator switch circuit breakers

Note: These circuit breakers come in different amps that they trip at and different voltages so you must select the right amps and voltages for your solar system. Don't just buy the one shown here because that might not be the right value for your solar system.

This goes between the solar panels and the charge controller to turn off power from the solar panels.

You should select the circuit breaker amps to be above your solar panels maximum amps but not too far above that it never trips.

Crimping Tools

Ferrule Crimping Tool

This is optional but can be used to crimp the bare wire ends that are used to connect to the charge controller.

Ferrule Crimping Tool Kit, LUNEY Crimper Plier with 1250PCS Wire Ferrules Kit Wire End Terminals, Self-adjustable Ratchet Tool Set for AWG 23-7 Cable connectors, 0.25-10mm² ($21.99 10/27/2025)

MC4 Crimping Tool

Charge controller to solar panel cable

Choose the cable length you need to go from your solar panels to your charge controller. Most solar panels have MC4 connectors; therefore, the MC4 connector plugs into your solar panels MC4 connector and the other end is bare wire that connects to your charge controller.

You can buy wire with a MC4 connector already connected or buy bare wire and connectors and put the connector on the wire yourself. If you are going to put on the MC4 connectors yourself a MC4 crimping tool would make the job easier.

MC4 connector to MC4 connector

Bare wire to MC4 connector

Most charge controllers take bare wire on the charge controller side and MC4 connectors on the solar panel side.

5 Feet 10AWG(6mm²) Solar Panel Wire, 10 Gauge 5FT Black & 5FT Red Tinned Copper Extension Cable Kits with Female and Male Connector for RV Home Boat and Any Other Off-Grid Applications ($6.99 11/6/2025)

Bare wire

MC4 Connectors

BougeRV 12 PCS Solar Connectors with Spanners Solar Panel Cable Connectors 6 Pairs Male/Female(10AWG) ($9.99 10/19/2025)
100PCS Solar Panel Connector IP67 Waterproof Connector Male/Female 50Pairs with 2 Spanners ($33.99 10/30/2025)

Charge controller to battery cable

This cable connects the charge controller to the battery.

The charge controller typically takes bare wire that installs under screw terminal on the charge controller end and 3/8" ring terminals on the battery end.

Bus bars are recommended when using multiple batteries and will help keep the batteries in balance. When using an optional bus bar the wire from the charge controller will go to the bus bar instead of directly to the battery terminal. In addition, you will need separate wires from the bus bar to the battery terminals.

Wire size recommendations by amperage

30-amp controller: 12 AWG (for short runs)
40-amp controller: 10 AWG (for short runs), 8 AWG (for longer runs)
60-amp controller: 8 AWG
80 & 100-amp controller: 6 AWG
For longer runs (over 10 feet): Always choose a larger gauge wire. For example, a 40-amp controller with a long wire run may need 6 AWG, and an 80-amp controller with a long run may need 4 AWG.