Power Tools Battery Tips: Mod a cordless power tools battery to run with wall current

May 10, 2010 - PRLog -- Mod a cordless power tools battery to run with wall current
Adding a jack to the battery of a cordless tool so you can run it off of wall current and keep it close to full power all the time. This might not be the brightest idea to do with NiCd batteries, but if you have a skunked battery you can't lose much.

I decided to do this project with the Black & Decker Firestorm 18V system, but you could do it with nearly any cordless tool set.


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Things you'll need:
-Cordless battery and charging unit
-Soldering iron and solder
-Wire strippers
-Electrical Tape
-Something to dismantle your battery (In this case Hex wrenches and Torx bits)
-Two wire quick-disconnects (they usually come in male-female pairs)
-Power drill and bit
-Knife or x-acto

You may also want:
-Hot glue gun or epoxy
-Clamps


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step 1 Dismantle your power tools battery
Warnings!: -This will void every sort of warranty you could hope to have. Proceed at your own risk -Discharge your battery before working on it. This should be a no-brainer Each battery is made differently, so I can't give specific instructions on how to take it apart. Mine involved really annoying hex screws that refused to budge. Then I realized they were Torx - h…


step 2 Find your anode and cathode (+ and -) and wire the quick disconnect to it
Locate your anode - this is going to be usually white or red. If you've forgotten your cell setups, this is the positive terminal. In my battery there was a white wire for the anode and a common cathode (a plate that just connects all of the cells' cathodes). Drill a hole in the side of the battery casing so that it's convenient to run a cord out of. Run the wires …


step 3 Reassemble your battery
Put the battery back together. You will probably have to force it a bit in order to get the wires to fit in the casing. Also, make sure to put back any springs or things that lock the battery to the tool. I used QuikGrips to hold it together while putting the screws back in.


step 4 Modify the wall adapter
Now to modify the power cube to attach to the battery. Since you're going to be drawing a bit more current, you will might have to replace the original cable. Mine was mysteriously cut a while back, so I used the opportunity to upgrade to an extension cable. Cut the power cube from the part that clips to the battery. If you're going to replace the cord, leave about 1.…


step 5 Finished! - using the power tool
The battery and charger should be all set now. NiCd batteries are a pain in the ass sometimes because of dendrites and charge memory and stupid stuff like that, so I think the best way to use this system is charge the battery full, then use it with the cord most of the time. The wall unit as is doesn't have the capacity to run a power tool by itself, but the fully charge.

for details here:

http://www.pioneer-electronics.co.uk/Mod-a-cordless-power...

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