Step 1: Tool and Supplies
- Old Drill to fix
- New Harbor Freight Drill http://www.harborfreight.com/cordless-drilldriver-with-keyless-chuck-38-18-volt-68239.html
- Hack saw
- Solder and Tools
- Nuts, bolts, screws
- Sander, or sand paper, or file
- Working drill to use in the repair ( this project takes 3 drills, is this a record? )
Step 2: Test the Old Drill
Step 3: Dissect the Old Drill
You just need to take apart the old drill enough to get at the leads for the old battery contacts, perhaps you can do this without any disassembly. In my case I removed the the screws that are transverse to the drill bit and the two sides came apart. Add wire extensions, ideally red for positive and black for negative. Solder. You can then put the drill back together. ( in my case a bit too much of the drill came apart, but I just put the parts back ) You may want to test again through the new leads.
Step 4: Dissect the Harbor Freight Drill
All you need from the drill is the power connector at the base of the handle. I put the drill in a vise and used a hack saw. The handle is pretty much empty here but you may cut the wires which is ok. Cut above the screws holding the two sides of the bottom of the handle together. I wanted to get as close to these screws as possible so I used a power sander to get closer and smooth the cut. You could use a different sander, a file, or whatever for this step. Try to think of a use for the rest of the drill, it has a nice motor, charger, gear reduction train, chuck. Post it as another instructable? Some have used drill motors for low powered vehicles.
Step 5: Attach the Battery Connector
I planned to just use some countersunk bolts, you need countersunk to keep the connector smooth where the battery slides in. A fly in the ointment was the bolt at the rear of the drill. It would not come through the top of the handle. To fix this I fastened ( a bit of glue and some screws ) a block of wood inside the hollow part of the handle. Then I put a countersunk screw from the connector into the block. Also connect up the leads. The pictures should make it pretty clear. It is a bit hard to remove the battery as the release is under the flange of the original handle, you may want to cut this away.
Step 6: Start Drilling
You can buy more batteries for the drill from Harbor Freight, but often buying the whole drill is just as cheap. As always with Harbor Freight watch out for sales and coupons.
Remember if you Drink don't Drill see: http://home.earthlink.net/~foghornj/drinkand.html