HHO gas, a blend of hydrogen and oxygen, is emerging as a clean, efficient fuel source with the potential to reduce emissions and improve fuel efficiency, offering a sustainable alternative to fossil fuels. Produced via water electrolysis, HHO gas generation is scalable for diverse applications but heavily reliant on renewable energy sources like solar power. This study employed a solar-powered electrolysis system to produce HHO gas, analysing its performance under varying weather conditions. Results showed peak production of 1.2 L per minute (LPM) at 1440 W/m2 irradiance on sunny days, with current output reaching 66 amps. Cloudy and rainy conditions significantly reduced efficiency, with production and current dropping by over 50 %. High electrolyte temperatures, reaching 90 degrees C on sunny days, necessitated system shutdowns to prevent overheating. Another solution to avoid this is to divert or utilise the portion of electricity for other purposes. The research underscores the need to optimise operations during peak solar energy periods and incorporate adaptive controls to maintain efficiency across diverse climates, providing key insights for enhancing solar-powered HHO gas systems.