Ever wonder how they weld those little tabs on to batteries to make battery packs? No? Oh. Well I did.
There are 2 ways.
Spend $5k and buy a commercial unit or spend $200 and DIY!!
The process is fairly simple. The power supply (on the left) chargers up the capacitor (top). Since the capacitor can represent a very large electrical load I have put a resistor in line with the power supply. This means it takes a few seconds to charge. The resistor is actually a 20watt halogen light (Bottom left).
Next to the light is a simple volt meter (bottom centre).
Once the capacitor is fully charged you place the electrodes (seen externally on the end of the thick cables) on to a nickel tab resting on the battery and depress the foot operated switch which triggers the silicon controlled rectifier SRC ( Bottom right). This then dumps the full charge of the capacitor onto the tab and welds it to the battery very quickly with minimal build up of heat.