This is my first Instructable so be kind-ish.
I needed a way to charge 6 AA NiMH 2500Mah batteries for a label maker. I had the batteries and the charger so as always. I went to the hardware store and started grabbing. No not really I remembered seeing a PVC battery Pack and used the idea myself (Insert Credit to Instructable author here).
So here goes.
Step 1: Tools
Drill Bit (correct size for bolts you have chosen)
Step 2: Materials
1/2 PVC SCH 40
1/2 PVC Cap
1/2 PVC Pipe to Male Water Hose Adapter
Plastic Water Hose Female Cap
1 spring (to fit into the 1/2 PVC
Step 3: Charging Lugs and End Caps
Center your drill bit and let it spin. Safely with all required safety equipment (at your discretion)
Drill a hole in the center of both end caps. Put the Bolt and nut through the water hose cap and tighten down.
Now take your spring and crimp one end so that the bolt head doesn't completely slip through. Then insert it in the PVC end Cap and Tighten down.
This step will require trial and error as far as bending the spring around to get it centered in the cap.
Step 4: Measure PVC and Fit the Ends
I needed to charge 6 batteries at once.
I placed the batteries end to end with the spring one side and marked it. Remember to cut it just a bit short to allow for spring compression so the batteries will make contact with the charging lug in the water hose cap but not to short that you have to force them in to screw on the cap.
***NOTE OF IMPORTANCE***
you want the pipe long enough to hold the batteries taking into account for the Depth of Caps and Fitting
Now seat your end can and water hose adapter completely on the PVC and test fit with the batteries, the yellow cap should screw down far enough that the batteries don't slide.
I didn't glue my ends on in case I need to change the number of batteries to be charged later.
Step 5: Test for Battery Voltage
Insert your batteries with the positive side up (toward the water hose adapter). this will make it easier to get good connections between the charging lug and the battery on the spring side.
Once you make sure there is some Voltage on the two charging lugs you are Finished. If there is not then you may need to adjust the length of your pipe or the spring to make it sure it is centered on the Negative end of the batteries.
You may also have to add a washer under the head of the positive lug to change the depth of the bolt head
Remember There are exposed terminals with this device.
I DO NOT RECOMMEND LEAVING BATTERIES IN THE TUBE WHEN NOT CHARGING TO PREVENT DISCHARGE OR SHORTS.
Step 6: Disclaimer
SAFETY SAFETY SAFETY. IF YOU CAN'T DO THAT IT IS ON YOU. IF YOU NEED HELP WITH THE TOOLS AS SOMEONE WHO KNOWS HOW USE THEM CORRECTLY.
If is a duplicate instructable SORRY. I will give credit where it is due.
My idea was generated from this instructable on using PVC for a battery pack
Thank you for you help in creating this idea with your battery pack idea.