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by BrianH (/member/BrianH/)
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Posted:
May 24, 2006
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BrianH (/member
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(http://cdn.instructables.com/FLV/KNMV/QOLEP27ZHT8/FLVKNMVQOLEP27ZHT8.LARGE.jpg)
I hate it when my cordless drill gives up in the middle of a job. It seems that the
supplied battery packs just don't cut it. So I opened up the battery pack and
replaced the NiCads with much longer lasting NiMH batteries. Now I get a much
longer use between charges.
(/id/Rechargeable-BatteryCapacity-Tester)
(/id/Full-Size-R2D2on-a-budget)
(/id/Pirate-Ship-Helm)
Tags:
Drill (/tag/type-id/category-workshop/keyword-drill/)
battery (/tag/type-id/category-workshop/keywordbattery/)
Related
(http://cdn.instructables.com/FJZ/IHMD/UQBEP27ZHU7/FJZIHMDUQBEP27ZHU7.LARGE.jpg)
My battery pack had 4 Torx screws (I later replaced with regular Phillips screws
for easier access). Inside you'll find 10 NiCad batteries. They appear to be just a
bit smaller than 'C' cells, and all attached together in series. 1.2 volts X 10 cells
= 12 volts. The cells are marked as 1300 mAH which is why they don't last very
long. You will probably want to photograph the arrangement of batteries since
you will need to make a new pack look just like this. Also notice the thin insulator
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that keeps the top battery from shorting against the batteries on the bottom.
(http://cdn.instructables.com/FNF/6IBE/3SXEP27ZHV6/FNF6IBE3SXEP27ZHV6.LARGE.jpg)
Aquire a new set of identically sized batteries. In my case the size is called
'Sub-C'. I got them at BatterySpace.com for $24.00. They come with tabs
attached. Carefully assemble the new cells into the same arrangement as the
original, and solder the tabs appropriately. Be careful not to short out a cell while
assembling it - even briefly! You will also need to scratch the surface of the leads
before soldering and put a thin coat of solder on each tab before assembly
(called tinning). Re-assemble and test. Be sure to re-use the fusable link that
came with the original battery pack
Step 3: Notes
(http://cdn.instructables.com/FQW/S92S/IVREP27ZK9F/FQWS92SIVREP27ZK9F.LARGE.gif)
Capacity:The new batteries are rated at 3000 mAH, so expect more than twice
the run time than the original pack. You may wonder -- will the higher capacity
hurt the tool? No: the important thing here is that the voltage is the same, but
you may end up working the tool harder with the increased capacity, so don't
over-do it. I've been using it for about a year and a half, and it's been excellent.
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(http://cdn.instructables.com/FV3/HBJD/GO2NLTGD/FV3HBJDGO2NLTGD.LARGE.jpg)
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pack to work on. This one is a 19.2 volt pack, but still uses the Sub-C Ni-Cd
batteries that my old drill used. Once again, I found that there were a few cells
that were bad - making the entire battery pack useless. This time I'm just going
to replace the bad cells with identical cells. The procedure is the same, but this
time I decided to make a video of the soldering which can be a bit tricky.
I've already removed the bad cell from the pack - now I'm going to replace it with
a good one.
Be careful not to short circuit any of the cells while soldering.
(I should have cleaned off the soldering tip better before I started)
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russ_hensel (/member/russ_hensel/)
9 days ago
Reply
Just a note to let you know I have added this to the collection: Cordless-Drill!
(/member Battery-Maintenance
/russ_hensel/)
>> http://www.instructables.com/id/Cordless-Drill-Battery-Maintenance/
(http://www.instructables.com/id/Cordless-Drill-Battery-Maintenance/)
Take a look at a bunch of different/similar approaches to this project.
flag
vinniej (/member/vinniej/)
10 months ago
Reply
I have a multi-rotor that I crashed hard into a tree, wall, car and fence. Only my
second RC flight, ever. The quad copter then would only give an error
message via led's and would not work, I was devastated because I was out
$600.00 + I had saved hard for--took me a year. The LED code said "call the
company" RIGHT its in China and I gave up after several days of no answer
and multiple attempts to decipher Cinglish instructions. After two days of
internet searching I found a forum post buried on page 100K of a Google
search and it said a company rep for this quad copter advised him (the forum
poster) on the same problem recommending the following fix: Remove the
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"brain" (a DJI NAZA V-2 in this case) and hold it in your right hand about 7" above
a ceramic counter top with the writing on top, then rap it moderately hard on the
counter top .
I was reluctant but desperate so I tried it. To my total amazement it not only fixed it
but it flew better than ever after this "smack it a good one" fix.
flag
dodgeramman (/member/dodgeramman/)
11 months ago
Reply
I'm a bit skeptical but there is an easier way than doing this and doesn't cost
. batteries built up with crystal like particles (best way I can explain it )
that makes your NiCad batteries lose capacity over time . I've come across a
way try and zap them with a battery charger without taking them apart or
buying new batteries . I zapped a couple batteries I've had since buying a 4
piece set in the 1990's 18 volt Dewalt .Checking now to see how long it will
last just in a dewalt radio . Will post results later as I'm experimenting now .
(/member anything
/dodgeramman/)
flag
ironsmiter (/member/ironsmiter/)
3 years ago
Reply
The one thing I took away from this, that i will be grateful for as long as I can
remember, is the Soldering Video. That little trick/tip is going into the printed
long-term storage
flag
MTtoo (/member/MTtoo/)
(/member
/MTtoo/)
ironsmiter
3 years ago
Reply
ironsmiter (/member/ironsmiter/)
MTtoo
3 years ago
Reply
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I would upgrade to a 1w or eve a 10w resistor. they're only a dollar, and the
added safety is worth it, imho.
You'll have to check VERY carefully. but if all the packs are NiCd, then
12-14 hours with the charger, and resistor described should give you a full
charge. It should also be safe if you forget and leave it on a little too long.
NiCd can survive almost indefinite charging at 1/10C rate. The extra energy
gets converted to heat, and exits the battery through the cell wall.
Bear in mind, quick chargers like my original, have very sophisticated
circuitry... but mine charged at almost 1C. it did shut off after that though,
as a safety feature. Charge at 1C for 10 hours, and you better have the
fire-department on speed-dial, cause around hour 3, it's gonna go
Fwoosch!
Consider some googleing on "homemade NiCd chargers.
Tons of info is to be had at RC groups. they use packs much like these to
fly their planes(though they're starting to switch over to li-po and li-fe)
Doh, just forgot.. you'll have to measure the ACTUAL voltage, under load,
because you're gonna get a voltage drop over the rectifier. You're going to
have to recalculate using the lower, measured voltage.
flag
MTtoo (/member/MTtoo/)
(/member
/MTtoo/)
ironsmiter
3 years ago
Reply
ironsmiter (/member/ironsmiter/)
MTtoo
3 years ago
Reply
15/02/2015 20:54
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ironsmiter (/member/ironsmiter/)
ironsmiter
3 years ago
Reply
oh, and to be VERY CLEAR for the folks trolling in the background, or
the years to come...
(/member in
/ironsmiter/)
Dr.Bill (/member/Dr.Bill/)
(/member
/Dr.Bill/)
ironsmiter
1 year ago
Reply
The un-rectified AC would just blow the wiskers off and the NiCad
would work good again. Just have to limit the AC time to a few
seconds...
flag
bclamore (/member/bclamore/)
2 years ago
Reply
The Dremel tool effectively removes the surface oxidation. I suspect this is
(/member why the solder sticks. You could probably do just as well with alcohol and
/bclamore/)
some flux. A rougher surface should also help prevent the solder site from
being flaked-off. Dremel tool looks like an easy solution too.
flag
endadmcc (/member/endadmcc/)
2 years ago
Reply
mygiveaway (/member/mygiveaway/)
2 years ago
Reply
(/member I've
/mygiveaway/)
Does anyone know what each of these components do and how I can replace
\ bypass one or all three to get the battery to charge again?
Info: the red component was glued to the top of one of the other cells in the
pack.
(http://cdn.instructables.com/FJQ/COUH/GZGT3NG9
/FJQCOUHGZGT3NG9.LARGE.jpg)
(http://cdn.instructables.com/F79/GIDZ
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(http://cdn.instructables.com/FUX/AAEF
/GZGT3NGA/F79GIDZGZGT3NGA.LARGE.jpg)
/GZGT3NGB/FUXAAEFGZGT3NGB.LARGE.jpg)
(http://cdn.instructables.com/FOK/LR94/GZGT3NGD/FOKLR94GZGT3NGD.LARGE.jpg)
flag
mygiveaway (/member/mygiveaway/)
mygiveaway
2 years ago
Reply
budrootbeer (/member/budrootbeer/)
3 years ago
Reply
Does someone make and sell a converter to actually plug in your 19.2 sears
drill and saws? Sometimes at home you don't always need to be
cordless.
(/member cordless
/budrootbeer/)
flag
Dr.Bill (/member/Dr.Bill/)
(/member
/Dr.Bill/)
budrootbeer
2 years ago
Reply
I removed the battery from my drill motor and just connected a wire to
each terminal with clips that fit and plugged the other end into my 25
amp switching power supply and it works good. lotsa power.
flag
mymatemark (/member/mymatemark/)
2 years ago
Reply
Ni-Cad & Nimh are good at certain price points but in the long term the best
performance comes from Lithium or Li-ion as they last longer, do not
have a memory, they are lighter & provide more power right through to the last
bit of use. Lithium or Li-ion batteries have no memory so when you stop using
the power tool & you go to use it again in a few months the battery has the
same level of power as previous. Another good thing is they do not react to
extreme heat & cold the way Ni-Cad or Ni-MH does.
(/member battery
/mymatemark/)
instructableken (/member/instructableken/)
2 years ago
Reply
I don't know if anyone actually mentioned the size name of the batteries used
(/member for power tools. It is "Sub C". I buy tem on eBay and always buy NiMH. Many
/instructableken/)
of my older tools are NiCad and the NiMH gives you more power and life.
flag
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jamesjghome (/member/jamesjghome/)
2 years ago
Reply
I thought I was the only Mcgiver left but I see not. When I was a child, my Dad
and mom called me screwdriver fingers due to the fact that I had to tear
something open and see how it worked; even though not broken I just could
not resist
I did the battery thing about tens years ago when I discovered the C batterers
matched my flashlight. Aside from all the data and info in above links, if you
can imagine and interpolate you can do this in about most everything
Thank God, Men are still men
flag
MACSWAG (/member/MACSWAG/)
3 years ago
Reply
Thank you so much for the very helpful post,I've just thumped one of my
18v.bats on the deck and it is now charging,well the charger light is
bright so I'll test in the morning,the other one same procedure the charger light
comes on but quite dim , any more suggestions please or how to check which
cells are duff would be helpful ,I'm in the U.K. so don't have the same suppliers
as you chaps across the sea,
(/member Draper
/MACSWAG/)
MAC.
flag
ironsmiter (/member/ironsmiter/)
MACSWAG
3 years ago
Reply
Take your two packs, and rebuild one good one out of them.
With the now empty battery case, rebuild it will ALL fresh cells.
That should get you the best bang for your buck/euro/pound.
Keep any extra good cells for when, not if, WHEN, your newly repaired
pack
kills another of it's cells. When you run out of THOSE spare cells...
recycle all the old cells, and rebuild with new tabbed cells for what is
now the third lease on life for that battery pack :-)
Now, we're 10-15 years into the future of your tool, and it's probably
worn out. Time for a new cold-fusion powered drill.
flag
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ironsmiter (/member/ironsmiter/)
MACSWAG
3 years ago
Reply
You don't need the same suppliers, for checking which cell is bad, just
(/member any old cheap volt/ohm meter.
/ironsmiter/)
As for buying the new tabbed battery cells... don't we all buy them from
the same Chinese manufacturers?
Check the image in step three.
If the battery is freshly charged, that "light bulb load" is pretty important.
It helps bleed off the "surface charge" on the cells, and gives you a
"working voltage" to measure.
Test the cell voltage after 2-3 min of running the light.
eel_dahc (/member/eel_dahc/)
3 years ago
Reply
I just redid one of my Craftsman 19.2 batteries. What I did was a little bit
(/member different. I bought an 18v battery pack from Harbor Frght (HF). It was a gamble
/eel_dahc/)
really because I didn't know for sure how the batteries were arranged in the
pack. Luckily they are arranged in the same shape, however they are
connected differently. Luckily though there are wires already soldered and
coming off of the pack that are long enough to make it work. My original
craftsman pack had various bad cells. But, the cell connected to the
terminals(the one on the top of the pack) was still in great shape. So, I snipped
the nickel strip off the bottom( leave as much as you can though so when you
solder you can hold the strip with pliers to sink the heat ) side of the top battery
and the negative wire going to the rest of the pack. I then carefully pulled out
the fuse/resistor wires making sure not to damage them. Then I soldered the
red wire coming from the HF battery to the bottom of the cell with the terminals
on it and the black wire from the HF pack to the black wire going to the cell
with the terminals I then tucked it all into the craftsman battery case, put the
top on, screwed it back and then charged it up. Perfect. If you do this make
sure the battery with the terminals is still good. If it is not then you will have to
replace that cell with a new one. Best of all, the pack cost $10, on sale for
$12.99 with a 20% coupon.
flag
gsnoorky (/member/gsnoorky/)
3 years ago
Reply
That pic looks like my 12V Sears Companion drill battery--I'm working on that
(/member now. It doesn't seem to work very long in the drill--a few secs, and it slows. I
/gsnoorky/)
did do the battery starter trick--it was at ~10V--now, it's at 13+ V. I rapped it on
the floor a few times and put it back on the charger--instructions say to leave it
on for several hrs.--maybe even six.
I'm also working on my two Milwaukee 18V "Power-Plus" batts. Using the
same trick, one seems now to be the usable battery for the drill I had
loved--the drill turns solidly again! The other batt may be too far gone. It did go
from 0V to ~3.2V, though. The charger doesn't accept it yet. I'm nowhere near
ending the fight for it: I'll cut it open and go NiMH, if necessary.
Big box HW stores want $70-$80+ for such Milwaukee 18V batteries: Well, I
then knew that the expensive drill screw wished to turn into myself! Amazon
was somewhat more reasonable: $50+, yet, I haven't checked lately. Thus, I
haven't used my originally priced $200+ drill for a couple of years. I was about
to give up and purchase Skil or B&D--or even cheapo HFT or Big Lots!
(These Milwaukee batteries don't use the familiar vertical post most drill batts
often use. Three side-shielded terminals "slide" horizontally into the drill
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bottom or the charger. As for checking such unmarked terminals for polarity, use a
voltmeter to find the terminals which give a positive voltage reading--perhaps after
charging. For this Milwaukee 18V "Power Plus" ni-cad battery, apparently the
terminal on the far left (terminal side up and terminals facing you) is neg (-)--the
one directly next to it, on the right, is the positive terminal (+).)
Thanks for the great inputs here!
flag
cjq (/member/cjq/)
(/member
/cjq/)
3 years ago
Reply
Hi folks, I've read comments about re building 19.2 Craftsman packs, I still
have a problem. I bought 6,000 mah batts with tabs . The pack is complete
and has been charged . I had difficulty getting the charging to start. I found the
"old" battery pack corroded real bad. There is a tiny circuit component ,a
thermo device I think . I had to by pass thin device . I also found a "fuse" link ?
I think it is ,and that was broken,I by passed that also. Now here's my
concern,,the charger has a red lamp to indicate charging and a green for full
charge. Upon initial incertion the green lamp lighted . I know the new batteries
needed charging but the red lamp did NOT light. I left the pack on charge
overnight and the batts have charged to 21.5 volts surface charge . After a
little use the voltage dropped to 20.5 . How do I correct my charging difficulty.
The battery pack had NO temperature rise overnight. I'm thinking the Batteries
were in a trickle charge,,,make sence? I need some technical help Thank You
CJQ
flag
bricabracwizard (/member/bricabracwizard/)
cjq
3 years ago
Reply
I think if you want lots of answers post this question to the forum,
hopefully you'll get an answer soon, sorry I don't know the answer.
(/member
/bricabracwizard/)
flag
dcobrien2000 (/member/dcobrien2000/)
6 years ago
Reply
I have a set of 18V Coleman tools that came with 2 batteries. A while ago one
(/member became hard to charge and finally the other failed. I could not find
/dcobrien2000/)
replacements anywhere so I was faced with buying new tools (lots of $$). I
found this post and then the link about reviving rechargeable batteries, it said
that crystals can build up in the batteries and short them out. As a fix it
suggested hitting them with a blunt object. I opened up the batteries like this
post suggests and then whacked the cluster of batteries firmly with a rubber
mallet. To my surprise it worked, they now hold a charge and work great, no
new tools!
flag
solaralternatives (/member/solaralternatives/)
dcobrien2000
3 years ago
Reply
flag
snet (/member/snet/)
(/member
/snet/)
dcobrien2000
3 years ago
Reply
I recently ran a cross a Makita 6343D with 2 18v NI_CD batteries and a
charger on one of the free auction sites. When I received the drill one
of the batteries worked fine but the other wouldn't work at all, even
though the charger showed it "charging".
I wasn't too concerned since this whole lot was FREE but after reading
this I simply tried cleaning the metal contacts with rubbing alcohol and
lightly wacking the bottom of the battery with the rubber handle of a
hammer and POOF it started working again and holds a charge.
Thanks again for the great advice! =)
flag
fromjim (/member/fromjim/)
dcobrien2000
15/02/2015 20:54
(/member
/fromjim/)
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4 years ago
Reply
crazyg (/member/crazyg/)
dcobrien2000
4 years ago
Reply
flag
wupme (/member/wupme/)
(/member
/wupme/)
dcobrien2000
5 years ago
Reply
Its always surprising how many technical stuff you can fix with
whacking it. A wack actually fixed my digital preamp on wich an amp
technican gave up... Its also a cool way to fix something.
flag
-max- (/member/-max-/)
wupme
4 years ago
Reply
flag
jeff-o (/member/jeff-o/)
dcobrien2000
5 years ago
Reply
I'm delighted when the fix for a problem is "hit it with a hammer." :D
(/member
/jeff-o/)
flag
chenxinghao (/member/chenxinghao/)
5 years ago
Reply
I have two bad Craftsman 19.2 volts EX batteries that when pluging in to the
(/member charger it will go GREEN and no charging to take place. The bolts seem to be
/chenxinghao/)
the HEX type but my HAX drive could not go in. I noticed that there is a little
round/dot in the HEX openning that is preventing the tool getting in. What type
to tools to use to unscrew the bolts?
flag
Reply
I've seen those, they suck. I'd do a search for special security bits.
(/member
/The+Ideanator/)
flag
zappenfusen (/member/zappenfusen/)
The Ideanator
3 years ago
Reply
But in a pinch.
(/member
/zappenfusen/)
bgentle (/member/bgentle/)
flag
chenxinghao
It is a security screw that uses a torx screwdriver with a hole in the center.
Take a punch and punch the round dot as you call it out or use a dremel
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Reply
4 years ago
flag
Hubiewan (/member/Hubiewan/)
chenxinghao
4 years ago
Reply
Hi: I have broken off the little pin inside the security screw, allowing
(/member your regular torx bit to work. I do reccomend purchasing the security
/Hubiewan/)
bit set from Harbor Freight. On of them is cheap enough and quite
extensive. Hubiewan
flag
nukemmcssret (/member/nukemmcssret/)
Reply
Get a drill bit a little bit smaller that the head of the screw and drill out
screws. The head should come off both screws. remove
the cover and there should be some of the screw exposed. You then
grab it with a pair of needle nose and turn out the screw.
flag
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