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Battery Pack Rebuild - A DIY Beginners Guide

You probably here because you have a battery that you want to rebuild. The process is generally easy if you have any mechanical inclination. A basic understanding of battery polarity and the ability to solder is all you really need to do a battery pack rebuild. Watch the video and see if you have what it takes to rebuild a battery pack.

As a DIYer, I personally can not stand by and just not do something about my need. If I cant find what I'm looking for or I can do it better then it's time to do it yourself. The old saying "If you want something done right, then do it yourself," has long been a motto of mine. So building a battery would be right up my alley. I'll show you how to do it at home.

Getting Started: Battery Pack Rebuild

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  • Wire Strippers
  • Soldering Iron
  • 60/40 Solder w/ Flux
  • Heatgun / Blowdryer
  • Heat Shrink


Taking apart the battery pack

  1. Most batteries have a protective plastic that capsulate them. You will slip your knife or razor underneath it and cut gently outward to avoid puncturing the battery pack.
  2. At this point use your phone to take a couple picture of battery. In case you tear it apart and cant remember how to reassemble the new one.
  3. With your wire cutters, clip the battery connector as close as you can to the terminals so that it is reusable.

Reassembling the new battery pack

  1. Orient the new batteries in the sam configuration as the old battery. Glue or tape the batteries together to make soldering easier.
  2. Now that your new batteries are together you can begin positioning the tabs to be soldered together.
  3. Be sure to tab in the correct orientation as your original battery. If your feel confident there right, then begin soldering. Be careful to not to heat up the battery. It will cause internal shorting.
  4. Next remove about 1/4in of wire jacket from end of connector and tin the wire with solder.
  5. Solder the wire to the correct terminal. Black to negative and red to positive.
  6. Lastly, use the heat shrink to cover your new battery pack and shrink down with your blow dryer or heat gun.

If you get lost or unsure what to do you could always just watch the video presented by BatteriesInAFlash. A DIY video on how to do a battery pack rebuild.

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