Opening up and modding a Li-ion battery and connecting into a gadget to recharge as needed

Why is this useful? When you're making an electronics project, like a portable handheld video game console system, it isn't easy to house a large battery pack inside the enclosure; however if the battery is able to be split into two parts, it means it is far easier to locate the batteries into your project. My hobby is making handheld portable video game consoles from consoles not designed to be used as such; so using good quality batteries are important to my work, and locating them in a case so they fit ok is important.

The batteries I am using here are Canon BP-915 or Canon BP-911 camcorder batteries as I use them in my projects for making handheld portable video game console systems. The principles and methods are however similar for other makes, brands and sizes of cells.

Li-ion batteries, like ones from camcorders, are made up in multiples of 3.7v cells, so for a 7.2v or 7.4v battery pack, you actually have two cells inside, for 11.2v you get three cells inside.

As long as you are careful, it is quite easy to segregate the cells and rewire the batteries, keeping the battery protection circuit in place, to stop over and under charging. Also in this guide, I cover how to connect the battery terminals to a charging jack.

Here's how... 

Step 1 Release tabs

There are two metal tabs on the sides of the battery, one is for the positive battery terminal and one for the negative battery terminal. Get a pair of pliers to snap off the plastic surrounding the tabs, and then with a small screwdriver, pry the metal tabs free. 

Comments

[anthonyyy0]

Also, the tact switches online are onlt solid round tops, unlike the ones in the video. are those okay to use and if so what dimentions? Sorry for asking so many questions, but it seems like i'm running into problem after problem.

[MODDEDbyBACTERIA]

There are various types of tact switches, all fine. Fancy joining and posting your queries in my forum, we can help you out more then? http://moddedbybacteria.freeforums.org/index.php

[anthonyyy0]

Thanks! This has nothing to do with batteries, but I can't find a reasonably priced PS1 LCD screen. Where do you get yours from, or is there a knock off brand that would cost less, but still get the job done?

[MODDEDbyBACTERIA]

Best screen is the Sony PSone screen, for the size. They cost about £30 on ebay, which is a fair price. I have some spare, similar price. (UK).

[anthonyyy0]

Great guide! I have two questions though, (my first portable system). Do I HAVE to separate the batteries or can I just remove the casing and leave the board attatched to the batteries? Also, how many li-ion battery packs do I have to use for a portable gamecube or N64? Does it depend on the screen I use?

[MODDEDbyBACTERIA]

You can keep the batteries in their shells if you have space, if you open the batteries up they can be separated if you like - optional. Battery separation is useful if your system can't fit a battery pack in its original size. Ideally two or three packs for N64 (eg the Canon BP-915 batteries), the GameCube needs 11.1v - 12v for the regulator board to work as getting 3 amps out of 1.9v by other means isn't easy. The Canon BP-915 cells aren't ideal for the GameCube therefore.

[funnyfoo0]

man this is useful cause at the moment i am building a ps1 portable

[MODDEDbyBACTERIA]

Excellent!

BTW, if you want a free guide for the PSone, etc, please have a look on my Wordpress website:  http://moddedbybacteria.wordpress.com