Introduction: Easy Nicad to Li Po Drill Conversion

I like to pick up early vintage cordless drills at thrift stores, they go for cheap especially if it has no charger and a dead battery, this vintage Sears 7.2 volt nicad tool went for $2 because it was the latter. I had on hand a T-Plug 11.1V 1500mAh 25C 3S VOK Discharge LiPO Battery that runs for about $8 U.S., including shipping, and decided to use it for the hack. I’ve found from past conversions that the voltage disparity isn’t much of an issue, the D.C. motors used in these products are pretty robust and can stand a wide margin of abuse and still live a long life.

Foreword;
The contents of the following Instructable represent the experiences and outcome of the author, no guarantee is made as to suitability of the repetition of the information presented, therefore careful study should be undertaken by those wishing to duplicate these results, including a self- assessment of prerequisite skills, knowledge, and understanding of the subject matter.

Thank you.

Step 1: Tear Down to Build Up

The first step is to remove the defunct NiCad cells and clean up the contacts and the housing that transfer battery power to the drill. I soaked and scrubbed them in vinegar to dissolve acid and corrosion, then rinsed well to neutralize them. A test fit confirmed that little more need be done to incorporate the new battery into the build.

Step 2: Route Power

I soldered a couple of 18 gauge wires to the contacts as down-leads to connect with the Lipo cells via a pair of insulated screw terminals instead of soldering them together, this would allow for easy replacement if it became necessary.

Step 3: Final Thoughts

The only case modification I made was to provide the balance charger connector a feed-through hole to allow hookup to my charger, and by using a salvaged set of contacts, I can easily recharge and balance the battery without any issues whatsoever. The weight decrease is remarkable and the output power is fantastic, so for $10 U.S. it’s a deal for me.

Comments

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nutt47 (author)2017-08-04

what is the blue box ? where did u get battery so cheep

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BeachsideHank (author)nutt472017-08-06

See comments below, all your questions are already answered. ☺

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4onthefloor48 (author)2017-07-30

good instructable, only concern I would have is that you took a 7.2 volt drill and repowered it with a battery that puts out 11.2 volts. Wouldn't this arrangement eventually burn the drill motor up ? You are going roughly 4 volts over rated output. Otherwise it's something I might consider for a backup drill.

author
Kuberkoos (author)4onthefloor482017-07-30

I have been using a 4.8V Bosch drill on 7.6V for several years, and no undue overheating, and on inspection no discoloration of the windings. These animals are fairly tough and forgiving.

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Yonatan24 (author)Kuberkoos2017-08-03

I think it could hurt the trigger/switch, if not the motor.

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big dawg1 (author)2017-07-30

Your idea is good BUT, you will be causing problems or fire if you don't add a couple of additional details.

Modern Li ion battery drills have built in protection circuits to cut the drill off when the Li ion batteries drop to a pre-determined voltage level. This is to protect the battery cell voltage from dropping too low and destroying it. Thus you need to add a protection circuit into the mix. A lipo low battery circuit will alert you when the batteries are reaching the critical low voltage level and let you know it's time to stop using the drill and recharge it. Here is an example of what I've used in the past for my conversions...

http://www.ebay.com/itm/New-2in1-Li-ion-Lipo-Batte...

A good instructable done by DIY Perks shows how to incorporate this...

HOWEVER, even he didn't discuss the need to balance charge the batteries once you have added this protection circuit.

For that, you should look at this youtube video (there are many others) on how to add the balancing circuit to the battery pack to keep you and your drill safe.

When charging the batteries you need to make sure that you are not over charging them. This is not a good thing! Some Li-ion batteries in a battery pack will charge more quickly than the others. With full power going to all the batteries, this could damage the battery that is already at peak voltage (or could cause a more serious issue, like fire).

For this reason, you should also build into the battery pack the ability to balance the batteries as they are being charged. The charger you are showing in your example has the capabilities of balance charging and cutting charging power to those batteries in the pack that gets to full capacity. But you must also include balance charging contacts.

Li-ion batteries are great if used properly but can be quite dangerous if you are not handling them or charging them properly.

My advice is that for anyone interested in doing this conversion, PLEASE do more research online on the proper way to do the above steps to ensure proper and safe use of Li-ion batteries. This is no joke and should not be taken lightly. Good luck to all.

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tomjasz (author)big dawg12017-07-31

BEST RESPONSE AND TUTORIAL HERE!!!!! THANK YOU!!!!! You may have saved a garage or house and lives!

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big dawg1 (author)tomjasz2017-07-31

Thanks Tomjasz for the kind words:

I wasn't trying to diss the presenter but felt I had to point out the additional steps that a novice should be aware of in order to have a safe conversion.

I've converted a few of my old drills several years ago and am very happy with how they perform now. Even so, I still don't leave them alone while they charge...just to be cautiously safe.

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Yonatan24 (author)big dawg12017-08-03

And don't over-dishcharge them! What a weird term.

author

WELL!!!

: '

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pblonsky (author)2017-07-30

Do you happen to have a parts list? Where did you get the battery and the charger? Are they made for each other? Also, why do you need to balance the charge when there appears to be only one cell pack? If you did balance change, how did you do it? What were your voltage numbers for the battery? Thanks! I have several good drills that I don't want to get rid of!

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nabzim (author)pblonsky2017-07-31

That is a common charger, they sell it on tons of sites ebay/amazon, and its rebranded a lot too, and it is made to charge every kind of rechargeable battery that i know of, as long as it has a balance connector(for lipos), but also does life, nimh, nicad, and even lead-acid (Pb) car batterys of any size. The battery he used was a 11.1 volt Lipo which has 3 cells, 3.7v each, so the balance connector should have 4 wires in total.

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pblonsky (author)nabzim2017-07-31

Do you think you can provide a link to one random charger on Amazon? This way I can get a model number or something so I can find a similar charger for my project. I really appreciate it!

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nabzim (author)pblonsky2017-07-31

Search on amazon for "imax b6ac" that is the charger i have, but there is a cheaper clone under the brand "hobbymate imax b6" that I'm sure works just as great, because it looks like it has just as good ratings. There are probably zillions of clones of that charger out there, and they probably all work fine and have the same functionality.

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definingsound (author)2017-07-30

$2 drill. $8 battery. $60 charger. I think this project is over the cost of a new drill for someone without a balance charger flitting about.

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SherpaDoug (author)definingsound2017-07-30

I just got a balancing charger from Amazon for $8 because I didn't want to wait for the $5 one from Hobby King.

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tomjasz (author)SherpaDoug2017-07-31

Sadly it's about a $1 value. Be careful that you don't start a fire. Charge in an ammo can closed with the watertight seal removed. That will contain any fire. Li Po stinks!

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tomjasz (author)2017-07-31

This is the most dangerous battery in the lithium lineup. undercharge and overcharge can both cause a fire. No alarm or low voltage signal can be a disaster. PLEASE use due diligence with these packs. RC folks are well versed but others may not be. LEARN about Li Po FIRST! 18650 cells would be far better or even repairing with the same cells!

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BobH160 (author)2017-07-31

I would use heat shrink for the terminals as unlike adhesive tape they will not be affected by heat that could make then drop off, only make them tighter.

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agis68 (author)2017-07-30

interesting instructable. I have the exact same Drill!!! I change the battery last year but when these bat pack dry out I will make your conversion....But is expansive one.....

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DavidJ187 (author)2017-07-30

I have in the past used old 7.2 & 9 volt drills and wired them with long leads and battery terminal clips. Used one to drill 5/8 hole through app. 12 in diameter utility pole..... Hooked up to truck battery, drilled like a champ. You are probably never going to hurt the motor, but if you do.... no big deal if it wasn't working anyway.

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bunillidh (author)2017-07-30

you do not have to use 11.1v lipos. There are smaller voltage lipos available through model boat, aircraft, and car suppliers. A local model shop should be able to supply over the counter and if not there are plenty on the internet

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ppsmith (author)2017-07-30

Is there not a risk of over-current or the battery falling below its minimum voltage and being damaged here? Maybe a protection circuit between the battery and the tool might be a good idea?

Good post though - it's a modification I've been considering making to my cordless drill for a while now as the battery begins to lose its original capacity.

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swaldo (author)2017-07-30

18650 batteries work as well.

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ghoulardi (author)2017-07-30

You might want to be careful with Li Pos as they can explode !

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Yankee DoodleR (author)2017-07-30

interesting, and having used LiPo before, a caution to anyone thinking they should go do this without understanding the dangers.

Drop this tool and damage the battery, the next time you charge the battery it will likely flare out, spurting flames and molten plastic. LiPo is not a battery technology to handle carelessly.

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tytower (author)2017-07-23

Thats good stuff Finding a battery to fit seems to be the difficult bit . After cleaning the contacts I have found it helps to recover them with solder if you can . Including the ones inside the drill head otherwise corrosion comes back quickly.

author
BeachsideHank (author)tytower2017-07-23

That is a good tip, thanks for sharing. ☺

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