Introduction

Here I am rebuilding, actually more building, a battery of the electric screw driver. The original battery is no longer available so I decided to build my own i order to continue to use the screwdriver. The battery cell I am using are 4/5 SC (sub C) size. Meaning they are 4/5 the size of a C-Cell. They are 23 x 34 mm in size with a capacity of 2000mAh and 1.2 Volts.

Image 1/3: Cut the plastic (I used a utility knife) away. Image 2/3: Now the three cells are clearly visible and the way they are connected in series. Meaning positive from one cell to negative on the next cell. Each cell separated by a rubber insulator Image 3/3: Now the three cells are clearly visible and the way they are connected in series. Meaning positive from one cell to negative on the next cell. Each cell separated by a rubber insulator
  • Here is the original battery. Three cells surrounded by a soft plastic sheathing

  • Cut the plastic (I used a utility knife) away.

  • Now the three cells are clearly visible and the way they are connected in series. Meaning positive from one cell to negative on the next cell. Each cell separated by a rubber insulator

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Image 1/3: The contacts on the old cells appear to be spot welded to make the connection. Image 2/3: Separate the connections with either a pair of side cutters or a pair of scissor. This will allow you to remove the insulators. Image 3/3: Separate the connections with either a pair of side cutters or a pair of scissor. This will allow you to remove the insulators.
  • Top to bottom on this image shows the insulator that is on the top portion of the cells. Next are the old three cells and bottom the new cells.

  • The contacts on the old cells appear to be spot welded to make the connection.

  • Separate the connections with either a pair of side cutters or a pair of scissor. This will allow you to remove the insulators.

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Image 1/3: Plenty of corrosion visible on each of the old cells. Image 2/3: To prepare the new cells, the heatshrink insulation from the contacts need to be removed. I used a utility knife to remove that. Image 3/3: To prepare the new cells, the heatshrink insulation from the contacts need to be removed. I used a utility knife to remove that.
  • Here all the cells are separated and the insulator removed

  • Plenty of corrosion visible on each of the old cells.

  • To prepare the new cells, the heatshrink insulation from the contacts need to be removed. I used a utility knife to remove that.

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Image 1/3: Align the positive contact of the first cell with the negative contact of the second cell. Image 2/3: Since the contacts will be soldered to each other, I did use some flex on the contacts prior to soldering. Image 3/3: Since the contacts will be soldered to each other, I did use some flex on the contacts prior to soldering.
  • Here is the first cell, insulation removed. Prepare all cells like that.

  • Align the positive contact of the first cell with the negative contact of the second cell.

  • Since the contacts will be soldered to each other, I did use some flex on the contacts prior to soldering.

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Image 1/3: Once proper alignment is obtained, I use a alligator clip to hold them in position. Image 2/3: Now solder the contacts together. I used a 30watt soldering iron with a blunt tip. Image 3/3: Now solder the contacts together. I used a 30watt soldering iron with a blunt tip.
  • Apply the flux to the contacts, in my case I used a cotton swab.

  • Once proper alignment is obtained, I use a alligator clip to hold them in position.

  • Now solder the contacts together. I used a 30watt soldering iron with a blunt tip.

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Image 1/3: Here is the next cell properly prepared. Image 2/3: First two cells, separated by the insulator, soldered together. Image 3/3: First two cells, separated by the insulator, soldered together.
  • Here is the first attempt. Luckily I noticed that I had forgotten to install the rubber insulator before going on to the next cell. Desolder the contacts to rectify this.

  • Here is the next cell properly prepared.

  • First two cells, separated by the insulator, soldered together.

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Image 1/3: Applied flux and alligator clip to hold it in alignment. Image 2/3: Solder the contacts together Image 3/3: Solder the contacts together
  • 2nd and 3rd cell prepared and being aligned.

  • Applied flux and alligator clip to hold it in alignment.

  • Solder the contacts together

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Image 1/3: The original battery was wrapped in some soft plastic. I decided to use 1 1/4 inch heat shrink tubing. Black electric tape might work just as well, but I used what I had on hand. Image 2/3: Heatshrink tubing placed over the cells Image 3/3: Heatshrink tubing placed over the cells
  • All three cells soldered together, positive to negative end, creating a series connection.

  • The original battery was wrapped in some soft plastic. I decided to use 1 1/4 inch heat shrink tubing. Black electric tape might work just as well, but I used what I had on hand.

  • Heatshrink tubing placed over the cells

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Image 1/3: Here is the two speed heatgun I use for my projects. Image 2/3: Simply apply constant heat to the tubing by moving the heatgun along the heatshrink tubing. Image 3/3: Simply apply constant heat to the tubing by moving the heatgun along the heatshrink tubing.
  • I placed a clamp from end to end. This will prevent any exposure to hot parts, will allow movement of the battery and still maintain alignment.

  • Here is the two speed heatgun I use for my projects.

  • Simply apply constant heat to the tubing by moving the heatgun along the heatshrink tubing.

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Image 1/3: Obviously the contacts are being than the connector. (The corrosion visible on the connector was cleaned of during the installation) Image 2/3: Trim the contacts with either a pair of sidecutters, or like in my case, use a pair of scissors. Image 3/3: Trim the contacts with either a pair of sidecutters, or like in my case, use a pair of scissors.
  • Here is the battery with the heatshrink tubing attached.

  • Obviously the contacts are being than the connector. (The corrosion visible on the connector was cleaned of during the installation)

  • Trim the contacts with either a pair of sidecutters, or like in my case, use a pair of scissors.

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Image 1/1:
  • Once the contacts are trimmed to size, the battery is ready for installation into the screwdriver. There is a separate guide for that. Total cost for this was around $9.00 for the cells.

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Conclusion

To reassemble your device, follow these instructions in reverse order.

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oldturkey03

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