Instructables
In my first instructable I needed to use an AA Battery to plate some copper onto a quarter, and I ran into an issue. I didn't have a battery holder, and I was too cheap to go out and buy one. So I scoured the internet looking for ways to solder a wire directly onto a battery and found nothing except that a tin strip could be welded onto a battery.

Like most people I don't have a welder so I started experimenting with using flux and other various agents until i finally found that filing the end of the battery would allow solder to pool. then I could solder a wire onto it easily.

This technique can be used for both normal and rechargeable batteries, so if you need to replace some rechargeable batteries in battery packs like the one from the Xbox 360 you can now do it. I also used it when making this instructable http://www.instructables.com/id/Copper-plating-made-easy/.

 Comments are welcome and appreciated
 
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Step 1: Materials

What ya need der:

-A Soldering iron

-Some rosin core solder

-A file

-Two pieces of wire preferably red and black to avoid confusion

-The battery

-Wire Strippers(not shown, but still needed)

-Some Skill with Soldering

Step 2: Filing the terminals

Take a file to the positive and negative ends of the battery and rough them up. make sure the whole surface of the battery terminal is evenly rough. its OK if you mess up the covering a little bit.

Step 3: Applying the Solder

Make sure your soldering iron is clean and then tin the tip of it. Secure the battery in a vice or clamp or something and make sure your iron is hot and ready. Using the iron heat up the terminal of the battery and apply solder, you don't have to heat the battery terminal all the way up to solder melting temperature, you can just use the iron to melt the solder. The solder should pool on the terminal, if it doesnt you need to rough it  up more, and try again.
ugur238 months ago

careful about coin batteryies . i have exploded one unfortunately.

but works with a123,nimh (dont heat so much) and 18650 cells. but dont try on flat li ion cells. i have puffed one when soldering. but lipo has external terminals and they safe

whayden1 year ago
Any reason that copper/conductive tape would also work?

I'm no good at soldering is why I ask.
whayden1 year ago
Any reason not to use some copper/conductive tape?
I try it to my battery but it not hold to strong.its not working
park473 years ago
I like this ,will try...Thanks..

And..I like .. Phil B says: too :)
" The people who make the most unkind comments are those who have published no Instructables and think they are experts on everything. It all looks a lot different when you have published something of yourself for others to comment upon it. Do not be discouraged."
ikssk3 years ago
Great instructable. I've been soldering on to batteries for years, mostly on power tool batteries. Never thought to make an instructable on the soldering on to the batteries it self, but i have transplanted cells from one battery to another without any problems. http://www.instructables.com/id/Battery-transplant-recycling-to-the-max/.
aduy (author)  ikssk3 years ago
i just took a look at your instructable and its very interesting how those big drill batteries are constructed. After I posted this instructable i saw another related one about reviving dead ni-cad batteries to brand new using a disposable camera's flash unit. http://www.instructables.com/id/Bring-Dead-Ni-Cad-Batteries-Back-To-Life/
ikssk aduy3 years ago
I have tried zapping my batteries like that, with no success. I think this technique requires to zap each cell individually, and it will only work on Ni-Cad.
aduy (author)  ikssk3 years ago
yes i figured as much, but still worth a try
carlos66ba3 years ago
Does it hold well? Does anyone know what the material of the battery terminals is??
aduy (author)  carlos66ba3 years ago
im going to delete the part about it not being very strong. i tried to pull the wire that was soldered onto the battery and the wire came off, but not in the way that your thinking. the solder remained on the battery and the wire broke off. so in conclusion, its as strong as a normal solder joint.
carlos66ba aduy3 years ago
excellent! thank you for (both) replies.
Phil B aduy3 years ago
Thank you for publishing your Instructable. Many years ago my mother traded in some stamp booklets, like S & H Green Stamps, and let me get a soldering gun with them. It is dual wattage (75 and 100 watts), and works well for tinning a battery as you described. A few years ago I bought a low wattage (15 watt) soldering iron similar to what you show so I would have something for more delicate electronics work. I always reach for the bigger soldering gun when I need to attach wires to a battery because it has more power and heats up the battery ends more quickly. I usually use fine sandpaper to rough up the metal battery ends. It works well, too.

As you publish more Instructables, you will find most people are appreciative and kind in regard to what you have done. The people who make the most unkind comments are those who have published no Instructables and think they are experts on everything. It all looks a lot different when you have published something of yourself for others to comment upon it. Do not be discouraged.
aduy (author)  Phil B3 years ago
thanks, its good to know others have done this. i looked across the inter tubes and hadn't found anyone else that had so i thought it would be good to share this knowledge.
Phil B aduy3 years ago
It is a good thing that you did this Instructable. Even if others have done it, there certainly are others who had no idea this is possible, nor how to do it.
aduy (author)  carlos66ba3 years ago
also the terminals of batteries are usually made from stainless steel
AndyGadget3 years ago
 
Yep, I've used this technique, but just be very careful if you try it on the 3V lithium coin batteries. It's possible but do it quick and clean as these heat up very quickly and can leak or burst.
aduy (author)  AndyGadget3 years ago
yes to avoid that just heat the solder using the iron.