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Material
1 Solder (3")
1oz Flux
1 Solder Iron
1 Heat Gun
1 Wire Stripper
Take the 2 solar power panels and cut all four wires to about 1" in length. Cut 1/4" of plastic off
of the tip of each wire with the wire stripper so copper wires are exposed. This exposed wire is
called a 'lead.' Cut the small heat shrink tubing into four equal pieces (1" each). Slide the small
heat shrink tubing onto both black wires.
Using a toothpick, paint leads with flux on a red wire from one solar panel, and a black wire from
the other solar panel. Put those two leads together, and solder using your piece of solder and the
soldering iron.
Slide small heat shrink tubing over the leads you just soldered together. Heat the tubing with heat
gun just enough for it to shrink.
Cut off the wire from your old charger to about 2.5 feet and strip off 2.5" of outer plastic from the
loose end. Cut 1/4" off of each of the inside wires to make leads. Slide the full length of the large
heat shrink tubing onto this main wire for later use in Step 6
On your main wire, slide a piece of small heat shrink tubing onto the red wire. Flux all loose leads
of main wire as well as the solar panels with the toothpick. Solder red leads from main wire and
solar panels together. Repeat with black wires. Slide heat shrink tubings over these soldered leads
and use heat gun to shrink.
On your main wire, slide large heat shrink tubing over the two soldered leads which connect to the
solar panels. Use the heat gun to shrink the tubing.
On the back of the solar panels, cover the two brass rivets with double-sided tape (so they don't
make contact with the Altoids tin.) Tape the two solar panels on the inside lid of the tin. Tuck the
main wire into the case and close. Go somewhere sunny (Florida is nice) and charge it up!
Time line