PLEASE DO NOT TRY THIS AT HOME... I HAD A FIRE WITH THESE BATTERIES. NO DAMAGE BUT THE HOUSE STINKS OF BURNING INSULATION
FAILURE MY OLD FRIEND
How not to build the battery pack: :less than 105 dollars. (You will probably need at least two)
Choose your weapons:
For the Deacon aka 1/2 ass method you will need the following items.
copper wire from a stripped electrical cord.
electrical tape (Black)
Duct tape the cloth kind not the vinyl
.
a black one foot wire (Color optional)
a white one foot wire (Color optional)
wire cutters
scissors
a multimeter or continuity tester.
Alcohol (Optional)
A Wooden jig. (optional but highly recommended)
A half empty kitchen table (or a cold workshop also not recommended)
30 nimh ‘c’ batteries at least 9500 ma.
what is heck is a jig you ask.
In this case it is a board with a rail on each side the space between the side rails is 2“ as close as possible along the whole 6+ inches in length.
Step one
Tear the duct tape so it is about an inch wide strip about a foot long. Lay it sticky side up in the jig track. Now lay five batteries (alternating the orientation from positive to negative end up) on top of the tape. Then fold the excess tape over to hold the batteries together.
Step two
Remove the batteries and stand them on their ends. This is what I call a string.
1. To do the actual assemble: cut on old electrical cord and strip off the insulation use the copper wire strands to connect the cells.
2. Solder a small piece of wire to join the tops batteries 2 & 3. then do the same with batteries 4 & 5 . continue until all batteries are wired in series to create 36volts
3. At this point attach a multimeter’s probes to each of the pack to check continuity.
4. This is where I go back and cover the pack with duct tape for insulation and to reinforcer the wire connectors.
5. Be sure to test for voltage often and not create any shorts from this points onward.
[6. strip two pieces of wire about ten inches long solder to the two end batteries cover the connection with duct tape as well.
that is pretty much all there is to it.
A tip about attaching this to your controller. For the building wire of the pack buy yourself a cheap extension cord at the walmart. About a buck and a half. Cut off the male end and attach it to the battery connection of your controller. It is important to use the male end since you don’t want a cord with power laying around to get shorted.
Use the female end of the cord to attach to the battery pack. (Important note) I used the big end of both the male and female ends as ground aka negative side of both the controller and battery. I also use the small side for the positive end. That is if you have to do a raw wire connection to the controller. Another benefit of these type ends, is that you can make multiple connections to the battery pack.
I have a male end and a wall switch on each of my chargers so I can turn them off even though they have a hot end when turned on. It allows me to plug them into the battery pack when it is one the Controller or unplug it and put two chargers on it for a faster charge and even a multimeter to read the live and resting volts.
Now I expect you know all I know about making a pack. Oh yeah now is the time to use the alcohol.
FAILURE MY OLD FRIEND
How not to build the battery pack: :less than 105 dollars. (You will probably need at least two)
Choose your weapons:
For the Deacon aka 1/2 ass method you will need the following items.
copper wire from a stripped electrical cord.
electrical tape (Black)
Duct tape the cloth kind not the vinyl
.
a black one foot wire (Color optional)
a white one foot wire (Color optional)
wire cutters
scissors
a multimeter or continuity tester.
Alcohol (Optional)
A Wooden jig. (optional but highly recommended)
A half empty kitchen table (or a cold workshop also not recommended)
30 nimh ‘c’ batteries at least 9500 ma.
what is heck is a jig you ask.
In this case it is a board with a rail on each side the space between the side rails is 2“ as close as possible along the whole 6+ inches in length.
Step one
Tear the duct tape so it is about an inch wide strip about a foot long. Lay it sticky side up in the jig track. Now lay five batteries (alternating the orientation from positive to negative end up) on top of the tape. Then fold the excess tape over to hold the batteries together.
Step two
Remove the batteries and stand them on their ends. This is what I call a string.
1. To do the actual assemble: cut on old electrical cord and strip off the insulation use the copper wire strands to connect the cells.
2. Solder a small piece of wire to join the tops batteries 2 & 3. then do the same with batteries 4 & 5 . continue until all batteries are wired in series to create 36volts
3. At this point attach a multimeter’s probes to each of the pack to check continuity.
4. This is where I go back and cover the pack with duct tape for insulation and to reinforcer the wire connectors.
5. Be sure to test for voltage often and not create any shorts from this points onward.
[6. strip two pieces of wire about ten inches long solder to the two end batteries cover the connection with duct tape as well.
that is pretty much all there is to it.
A tip about attaching this to your controller. For the building wire of the pack buy yourself a cheap extension cord at the walmart. About a buck and a half. Cut off the male end and attach it to the battery connection of your controller. It is important to use the male end since you don’t want a cord with power laying around to get shorted.
Use the female end of the cord to attach to the battery pack. (Important note) I used the big end of both the male and female ends as ground aka negative side of both the controller and battery. I also use the small side for the positive end. That is if you have to do a raw wire connection to the controller. Another benefit of these type ends, is that you can make multiple connections to the battery pack.
I have a male end and a wall switch on each of my chargers so I can turn them off even though they have a hot end when turned on. It allows me to plug them into the battery pack when it is one the Controller or unplug it and put two chargers on it for a faster charge and even a multimeter to read the live and resting volts.
Now I expect you know all I know about making a pack. Oh yeah now is the time to use the alcohol.
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