Introduction: How to Rebuild a Dewalt 14.4v Battery Pack
$80 for a new battery pack.
$25 to build your own.
Plus bragging rights!!!
$25 to build your own.
Plus bragging rights!!!
Step 1: Take Apart Battery Pack
remove the six screws that hold the pack together
carefully pull apart the two halves
take notes as to where things are and how they go back together
have a digital camera on hand for documenting dis-assembly
carefully pull apart the two halves
take notes as to where things are and how they go back together
have a digital camera on hand for documenting dis-assembly
Step 2: Remove Battery "pack"
carefully pull the battery pack out of the holder
Step 3: Document Everything
as you pull the battery "pack" apart
take pictures and draw pictures of how the 12 batteries are packed and connected so tightly
take pictures and draw pictures of how the 12 batteries are packed and connected so tightly
Step 4: Buy Replacement Batteries
Google 1.2v subC batteries
(1.2 * 12 = 14.4)
find your best price for 12 batteries
when you place your order make sure you have measured your battery cells and are getting the correct "physical" size
buy with or without tabs
without tabs is less expensive and the following steps will show you how to make your own tabs
(1.2 * 12 = 14.4)
find your best price for 12 batteries
when you place your order make sure you have measured your battery cells and are getting the correct "physical" size
buy with or without tabs
without tabs is less expensive and the following steps will show you how to make your own tabs
Step 5: Diagram the Connections
you will notice after folding and unfolding the string of batters
that the 12 batteries are wired in series pos-to-neg, neg-to-pos and so on
use the gummy insulator that you pried away from the top and bottom of the batteries to draw a template
then use a coin to complete the circles representing the batteries
draw a diagram looking at the batteries from the bottom
then draw a diagram of the batteries from the top
note each connection and how the battery tab is oriented
number the batteries on your diagram
while you are waiting on your new batteries to arrive in the mail
practice refolding the old battery string and placing it back into the holder
that the 12 batteries are wired in series pos-to-neg, neg-to-pos and so on
use the gummy insulator that you pried away from the top and bottom of the batteries to draw a template
then use a coin to complete the circles representing the batteries
draw a diagram looking at the batteries from the bottom
then draw a diagram of the batteries from the top
note each connection and how the battery tab is oriented
number the batteries on your diagram
while you are waiting on your new batteries to arrive in the mail
practice refolding the old battery string and placing it back into the holder
Step 6: Making Battery Tabs
the battery tabs, as you can see, need to be flexible
one very good source of material for making battery tabs is an old computer cable with an outer mesh
this is an old Firewire cable cut into small strips with the innards removed
the mesh can be squashed flat and take on solder very well
you will need eleven strips
cut extra just in case
put some flux on both ends and tin the ends with solder in preparation for soldering to your new batteries
one very good source of material for making battery tabs is an old computer cable with an outer mesh
this is an old Firewire cable cut into small strips with the innards removed
the mesh can be squashed flat and take on solder very well
you will need eleven strips
cut extra just in case
put some flux on both ends and tin the ends with solder in preparation for soldering to your new batteries
Step 7: Preparing the New Batteries
when your new batteries arrive, flux and tin both ends with solder
use a small iron with a nice large flat head
do not hold the iron on the battery for more than a second or two
wait
try it again until the solder melts and adheres to the battery
wear eye protection and use common sense
common sense says "overheat . . . and BOOM!"
take your time tinning the ends
one or two seconds at a time
flux is a must!!
use a small iron with a nice large flat head
do not hold the iron on the battery for more than a second or two
wait
try it again until the solder melts and adheres to the battery
wear eye protection and use common sense
common sense says "overheat . . . and BOOM!"
take your time tinning the ends
one or two seconds at a time
flux is a must!!
Step 8: Build Your New Battery Pack
arrange your new batteries on one of your template drawings
solder your homemade battery tabs to the batteries following your diagram for the bottom view
slowly, not overheating the batteries
sice you have tinned both the battery and the tab, soldering will go quickly
once you have the tabs on by following your "bottom view" drawing
flip the batteries over
set them on the gummy insulator you saved
and put the whole bundle in the battery holder
now solder the remainder of your tabs following your "top view" drawing
the first battery in the string of batteries has a special connector that is spot welded in place
use an old wood chisel to pry it away from the old battery, it pops off easily
tin that connector with flux and solder and solder it to you last new battery
the bottom of this battery may need a longer battery tab to get to the next battery in series
and the wire coming from this special connector goes to the last battery in your series of batteries
if you saved the gummy insulator from your earlier steps, place it on top of the batteries
otherwise cut a new template from some sort of nonconducting material and put it in place
now reassemble the two halves of your battery housing and screw them together
having total confidence in yourself drop your new battery pack into the charger
a steady red light means everything is good and the battery is charging
wait 5 minutes and try your drill
if all is good give it a full charge
but just to be safe . . . keep an eye out for smoke
solder your homemade battery tabs to the batteries following your diagram for the bottom view
slowly, not overheating the batteries
sice you have tinned both the battery and the tab, soldering will go quickly
once you have the tabs on by following your "bottom view" drawing
flip the batteries over
set them on the gummy insulator you saved
and put the whole bundle in the battery holder
now solder the remainder of your tabs following your "top view" drawing
the first battery in the string of batteries has a special connector that is spot welded in place
use an old wood chisel to pry it away from the old battery, it pops off easily
tin that connector with flux and solder and solder it to you last new battery
the bottom of this battery may need a longer battery tab to get to the next battery in series
and the wire coming from this special connector goes to the last battery in your series of batteries
if you saved the gummy insulator from your earlier steps, place it on top of the batteries
otherwise cut a new template from some sort of nonconducting material and put it in place
now reassemble the two halves of your battery housing and screw them together
having total confidence in yourself drop your new battery pack into the charger
a steady red light means everything is good and the battery is charging
wait 5 minutes and try your drill
if all is good give it a full charge
but just to be safe . . . keep an eye out for smoke
Step 9: Charge Your New Battery Pack
steady read light means all is good and the battery pack is charging
if you end up not calling the fire department
take yourself out for a beer
and brag about your experience!!
if you end up not calling the fire department
take yourself out for a beer
and brag about your experience!!