Introduction: Dummy Battery KL2CR5

another battery bypass! 
kl2cr5 battery's can cost more than 28 times the cost of a aa battery.(conservative)
. yes this is me praising the cheapo battery's again.
but this method is more of a guide to the dismemberment of the hideous kl2cr5 battery pack, alternative power sourses can be applied such as a mains or vehicle adapter go mental use a solar panel (if you can remember what the sun looks like)or a dynamo, theres even heat to electricity gizmos that i can only assume run on some sort of witchcraft.

materials
dead kl2cr5
solid core wire
battery snap and holder (2x 4xaa best)or connector of your choosing
solder
super glue
epoxy glue
hot glue (use your imagination)
heat shrink

tools
pokie stick
soldering iron
something to strip and cut wire
tweesers or forceps or pliers
knife optional
hammer or lump thing
lighter
small vice or clamping thing

Step 1: This Battery Is Worn Out

but seriously these are horrible, they seem to be permanently dead ,they cost too much to throw away lightly , most batterys found in the back of a draw will power a remote control for an evening, but not these they stay defiantly useless.

Step 2: ATTACK!

find the indentation and put something in at 45 degrees hold it as shown and tap the something with a hammer, it pops the battery case open

Step 3:

open both ends

Step 4: Remove the Guts

if something will not move easily look to see whats stopping it.

Step 5: Something Inside

im using strip board. its easy to solder to. and the glue can get a good grip on it as well. you can feel free to improvise at this stage

Step 6: A Bit of Wood With a Hole in Could Have Done This, or Even That Sirco? Stuff or Fimo or Whatever You Get the Idea

tie the bits together

Step 7:

glob some solder on, to hold everything in place

Step 8:

bend off the original battery contacts

Step 9:

add solder to the back of the contact. it gets hot doesnt wiegh much and there fore sticks to your iron , you will see.

Step 10:

hold the contact over the soldered wire, tweezers forceps needle pliers help here. poke the edges with the iron till it scrunches in place as the solder softens.

Step 11:

get a feel for where the contacts are supposed to be, theres a thinner part of the case where they sit.

Step 12:

apply a tiny amount of superglue on a hidden part of the contact and put it in place.this is just to keep it still when gluing it proper

Step 13:

take a moment to remove the superglue off your hands

Step 14:

proper glue. mix up some epoxy end goop it down the hole , it doesnt need filling just enough to have about 5mm or so in there, any gap filling substance will do here but i would not recommend blancmange .

Step 15:

i put a nice blob of hot glue on top to encourage the epoxy to dry quick .(regular readers will realize my fondness for the acceleration of epoxy)

Step 16:

strip and prep the wires ,not forgetting heat shrink. im using a battery snap because its close to hand, really should be using 2 of them,i want to keep the wires wedged in a battery compartment door to a minimum so any further connections will e made externally.
remember + is red and - is black

Step 17:

solder as needed,trim any pointy bits, heat the shrink try not to melt anything that doesnt want to be melted.

Step 18: WHOOOMPS MISTAKE ERLERT

make a groove for the wires to exit the battery.
only use your iron if you are confident you can clean it after.
note i changed the location of the wire exit to one end of the flat side,best for my battery door, for best results make a decision based on your application.

Step 19:

close it up, look out for any lumps or bumps that may get in the way ,trim melt or pull em off.before adding glue.

Step 20:

initial testing to make sure the contacts are contacting ok.

Step 21: Notes on Battery Substitution for Trouble Free Use.

a 1.5 volt aa battery is not as strong as a 1.5 volt lithium battery. it can do its job just not for long,

i found that using a 2 for 1 policy keeps everything happy.(as long as u use a parallel connection)

parallel is much happier if symmetry is used, it evens out battery ware

a series connection will not be good news, know the difference please.

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Bio: the a b c approach is not for me .all feedback welcome. thanks for looking. if you would like some assistance or are interested in ... More »
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