John in CR and I bought a roll of EVA. It is similar to the SylGard, but, comes as a sheet. You lay it on the glass, lay the made up cell strings on that, add another layer of the EVA and use a backer, like, TYVEK, house wrap, in a single layer. This is/was less expensive, and easier to work with, I think. Neither of us has built panels, though.
:lol:
Then, you build an oven out of big cardboard boxes, to fit the size of the glass panel, and make up a vacuum bag, using big trash bags, like, yard clean up type. You need some way to heat the whole package, typically, a ni-chrome wire from a scrapped electric dryer, old hot plate with exposed wire, etc. You need a fan designed to circulate the hot air, but, don't use a plastic fan blade.
The whole idea here, is to melt that EVA into one liquid state, which encapsulates the cells and connection box. The vacuum is used to squeeze out the air bubbles, so, a little tending as you heat the panel up, would be a good idea.
There is a set temperature that should be reached and held in the oven, to ensure the EVA is melted.
AS you have all the parts to construct a couple of panels, why not investigate the tutorial, over on Fieldlines.com, under the Solar board, there is a sticky of a 3 part tutorial on homemade panels.
There are discussion threads, also, and, it's looking like store bought panels, IF they are good brand, is actually a better deal, with the warranty .
Let us know if you give this a try.
Harold
