The Fenix-Store        
Page 1 of 2 12 LastLast
Results 1 to 30 of 60

Thread: Rewrapping a battery

  1. #1
    HKJ's Avatar
    Join Date
    Mar 2008
    Location
    Copenhagen, Denmark
    Posts
    8,564

    Default Rewrapping a battery

    Rewrapping a battery



    The above battery cannot be used anymore, it will short and might explode.
    The wrapping will sometimes break, luckily it is a fairly simple operation to fix it.



    Tools and parts needed



    I am using shrink wrap to repair the battery, due to the heat gun I uses, I have selected a low temperature type.
    When flat it is 29.5 mm wide, the inner diameter is 18.5 mm, it will shrink at 80 Deg. C.
    I bought a roll with 25 feet (7.6 meter) on ebay for $11 (Sellers name is atop_authentic_auction). This roll will last for more than 80 batteries. Fasttech has heat shrink in 1 meter pieces for less than $1.
    This heatshrink is also fairly thin, this is an advantage for some lights.
    Often heat shrink is specified in width of the flat tube, the table below shows the minimum sizes for different battery sizes.




    As a heat gun I uses a hair dryer, it is not the perfect tool for the job, but it can be used.



    I do also need something to measure with, my digital caliper is fine for that (A ordinary ruler could also be used).
    With a caliper, remember to cover the jaws or it will short the battery.



    To cut the heat shrink I uses scissors.



    Rewrapping



    I want the heat shrink tube to be about 3 mm longer than the battery at both ends, with a 68 mm battery this means 74 mm tube.



    The new tube for the battery has been cut of the roll.



    I uses the fingers to removing the old heat shrink, using a knife or scissors is unsafe.
    If there is two layers of heat shrink, only remove the outer layer.



    The "naked" battery, do not try to bend the protection pcb out to get a look.



    Putting the new heat shrink onto the battery.



    There will be about 3 mm extra at each end.



    Applying heat, rotate the battery and swipe the heat gun back and forth. If using a real heat gun, be careful with the fingers holding the battery!
    It is possible to increase the temperature by covering part of the air intake on the heat gun (This might also melt the gun if overdone).
    The battery must not be heated much (As long as it is possible to hold it, the temperature is fine). This is usual not a problem, the heat shrink will shrink long time before the battery is heated.



    Final result







    With a new covering, the capacity information is gone, to fix that I have added a label with capacity. I also included the date I got the battery.
    Last edited by HKJ; 02-25-2013 at 09:54 AM.
    My website with battery and charger information: lygte-info.
    More than 1000 reviews of batteries, charges and other stuff.
    Compare 18650 LiIon batteries or smaller (RCR123, 16340, 14500, 10450) LiIon batteries.

  2. #2

    Default Re: Rewrapping a battery

    Thanks for the excellent tutorial HKJ...I always learn something useful from your posts!

  3. #3

    Default Re: Rewrapping a battery

    Brilliant! I just bought some battery shrink wrap from Fasttech, just in case. Now I know how to use it should the need arrive. Thank you HKJ.

  4. #4
    Flashaholic jaycyu's Avatar
    Join Date
    Jun 2012
    Location
    Vancouver BC Canada
    Posts
    414

    Default Re: Rewrapping a battery

    I found both sellers. Fasttech is a website. I'll order some and see how it goes. Thanks for the picture tutorial.

  5. #5
    Flashaholic*
    Join Date
    Aug 2010
    Location
    ROLL TIDE!
    Posts
    1,013

    Default Re: Rewrapping a battery

    Great info! Thanks! I have a few 26650s and a couple of 26500s that need to be put back in service.
    SPY 007 XM-L2, BVH 150w Vec192 HID, Gen III Maxabeam, Barn Burner, FireFoxes III & IV, Mac's Customs 3840L & Damascus/Cu/Al Tri-EDCs, ma_sha1 FrankenMag, Drake, MF Scorpion 4x XM-L2, Tri-219 EYE10, XP-G2 X10

  6. #6
    Flashaholic
    Join Date
    Feb 2013
    Location
    N. Calif
    Posts
    153

    Default Re: Rewrapping a battery

    Very nice & clean looking results.

  7. #7
    Flashaholic jaycyu's Avatar
    Join Date
    Jun 2012
    Location
    Vancouver BC Canada
    Posts
    414

    Default Re: Rewrapping a battery


    Success!
    Thanks for the picture tutorial, HKJ.
    I bought the shrink wrap from FastTech's site, though they didn't have caution-yellow that fits 18650's.

  8. #8

    Default Re: Rewrapping a battery

    I rewarpped a couple of 18650 as per your directions and it was extremely simple and very effective.

    Get the material, used a heat gun on low, cut the correct length, get old wrap off, slide new wrap on, center the physical battery, slowly heat shrink wrap, done.

    Thanks

    Bob Weis

  9. #9
    Flashaholic* Derek Dean's Avatar
    Join Date
    Nov 2006
    Location
    Monterey, CA
    Posts
    2,132

    Default Re: Rewrapping a battery

    HKJ, thanks for putting together this little tutorial. I've got an 18650 cell that really needs to be re-wrapped, and with your thoughtful directions it now looks easily doable.

  10. #10

    Default Re: Rewrapping a battery

    Nice tutorial! I've used Fasttech's 18650 shrink wrap and it's ***perfect*** (and inexpensive). Some automotive shrink wrap is too thick.

  11. #11
    Retired Administrator Norm's Avatar
    Join Date
    Jun 2006
    Location
    Australia
    Posts
    9,515

    Default Re: Rewrapping a battery

    This is now a sticky.

    Norm

  12. #12

    Default Re: Rewrapping a battery

    Just rewrapped my first cell from an old laptop battery. Got some black heatshrink from Fasttech and it arrived this morning. a few wrinkles and it's a tiny bit off center, but it's a lot better then the electrical tape I had on it before.








    Thanks HKJ.

  13. #13

    Default Re: Rewrapping a battery

    This is a great tutorial. I know for some this stuff seems obvious, but these sorts of step by step tutorials really help a lot of people (and potentially) and help to curb questions.

  14. #14

    Default Re: Rewrapping a battery

    So far I have not seen any vendor selling the thicker, clear plastic wrappers used in most protected cells. Any information would be greatly appreciated.

  15. #15
    HKJ's Avatar
    Join Date
    Mar 2008
    Location
    Copenhagen, Denmark
    Posts
    8,564

    Default Re: Rewrapping a battery

    Quote Originally Posted by tatasal View Post
    So far I have not seen any vendor selling the thicker, clear plastic wrappers used in most protected cells. Any information would be greatly appreciated.
    You can find clear shrink wrap on ebay, but I do not know the thickness of it.
    Generally you want a fairly thin shrink wrap or you might have problem with fitting the battery in some lights.
    My website with battery and charger information: lygte-info.
    More than 1000 reviews of batteries, charges and other stuff.
    Compare 18650 LiIon batteries or smaller (RCR123, 16340, 14500, 10450) LiIon batteries.

  16. #16
    Flashaholic* kosPap's Avatar
    Join Date
    Mar 2007
    Location
    Naoussa Greece
    Posts
    2,823

    Default Re: Rewrapping a battery

    indeed...the clear wrappers are thicker. I think they are also available from fasttech

    Quote Originally Posted by walterwitt View Post
    Just rewrapped my first cell from an old laptop battery. Got some black heatshrink from Fasttech and it arrived this morning. a few wrinkles and it's a tiny bit off center, but it's a lot better then the electrical tape I had on it before..
    what method of heating did you use? I think yuo can work on it a bit more with a hairdryer. the off center is iether because of too uneven heat or not-squared cutting of the wrap

  17. #17
    Flashaholic jaycyu's Avatar
    Join Date
    Jun 2012
    Location
    Vancouver BC Canada
    Posts
    414

    Default Re: Rewrapping a battery

    Quote Originally Posted by kosPap View Post
    the off center is iether because of too uneven heat or not-squared cutting of the wrap
    : o
    I see

  18. #18
    *Flashaholic* LuxLuthor's Avatar
    Join Date
    Nov 2005
    Location
    CT
    Posts
    10,297

    Default Re: Rewrapping a battery

    It's too bad you can't find the typical 1 or 2 mil thick shrink that original cells are wrapped with. Most of the typical wrap sold is 5 mil (=0.005 inch)

  19. #19

    Default Re: Rewrapping a battery

    Received from FastTech the 18650 transparent and black shrink wraps. While the transparent are great, the black ones are crap, poor quality. First of all, they are a little loose when fitted, and when heated, it does not shrink cleanly like the blue, yellow (aa) and the transparent ones. Avoid their current black 18650 wraps.

    Btw, how do you eliminate the crease on both sides of the wrap to make it look just like from the factory?

  20. #20
    Flashaholic* kosPap's Avatar
    Join Date
    Mar 2007
    Location
    Naoussa Greece
    Posts
    2,823

    Default Re: Rewrapping a battery

    How did you heat it? It makes a difference if you used a good hair dryer or a lighter

    I make the main shrinking with the dryer and then work the creases with a BIC lighter. fast and not very close, if you overdo it the transparent wrap will tear on the crease.

  21. #21

    Default Re: Rewrapping a battery

    Quote Originally Posted by kosPap View Post
    How did you heat it? It makes a difference if you used a good hair dryer or a lighter

    I make the main shrinking with the dryer and then work the creases with a BIC lighter. fast and not very close, if you overdo it the transparent wrap will tear on the crease.

    I only used a good hair dryer. You never had the hair dryer remove the crease, only with the use of a lighter?

  22. #22
    Flashaholic* kosPap's Avatar
    Join Date
    Mar 2007
    Location
    Naoussa Greece
    Posts
    2,823

    Default Re: Rewrapping a battery

    On the Clear wrap i used yes...you need a bit more localized heat there

  23. #23

    Default Re: Rewrapping a battery

    Excellent tutorial. Thanks!

  24. #24

    Default Re: Rewrapping a battery

    Quote Originally Posted by kosPap View Post
    On the Clear wrap i used yes...you need a bit more localized heat there
    It worked! Thanks

  25. #25
    *Flashaholic* LuxLuthor's Avatar
    Join Date
    Nov 2005
    Location
    CT
    Posts
    10,297

    Default Re: Rewrapping a battery

    You can get a better result with an inexpensive heat gun than a hair dryer.

  26. #26

    Default Re: Rewrapping a battery

    Quote Originally Posted by LuxLuthor View Post
    You can get a better result with an inexpensive heat gun than a hair dryer.
    Saw your link...What noozle type do you use and do use the high or low mode? What is its advantage compared to a hair dryer? I can't seem to remove the crease with the hair dryer...

  27. #27
    HKJ's Avatar
    Join Date
    Mar 2008
    Location
    Copenhagen, Denmark
    Posts
    8,564

    Default Re: Rewrapping a battery

    Quote Originally Posted by tatasal View Post
    Saw your link...What noozle type do you use and do use the high or low mode? What is its advantage compared to a hair dryer? I can't seem to remove the crease with the hair dryer...
    You get higher temperature with a real heatgun, this is better at shrinking the wrap.
    On a hair dryer you can also partially cover the air intake to raise the temperature, you will not get as high temperature as a real heat gun and you might damage the hair dryer.
    My website with battery and charger information: lygte-info.
    More than 1000 reviews of batteries, charges and other stuff.
    Compare 18650 LiIon batteries or smaller (RCR123, 16340, 14500, 10450) LiIon batteries.

  28. #28

    Default Re: Rewrapping a battery

    Quote Originally Posted by HKJ View Post
    You get higher temperature with a real heatgun, this is better at shrinking the wrap.
    On a hair dryer you can also partially cover the air intake to raise the temperature, you will not get as high temperature as a real heat gun and you might damage the hair dryer.
    Really? I even thought that the heat from a hair dryer's was too much! Ok....

    Heads-up: The black shrink-wraps that I got from FT are really bad. It does not shrink evenly..not even properly. Never had any 'successful' finish with it.

  29. #29
    HKJ's Avatar
    Join Date
    Mar 2008
    Location
    Copenhagen, Denmark
    Posts
    8,564

    Default Re: Rewrapping a battery

    Quote Originally Posted by tatasal View Post
    Really? I even thought that the heat from a hair dryer's was too much! Ok....
    No, hair dryer is at the lower limit. The reason I uses a hair dryer in the above tutorial is because I expect most people has easy access to one.
    Usual when I uses heat shrink I uses a real heat gun or sometimes a lighter (It can be a bit tricky).

    Quote Originally Posted by tatasal View Post
    Heads-up: The black shrink-wraps that I got from FT are really bad. It does not shrink evenly..not even properly. Never had any 'successful' finish with it.
    It might be because you do not have enough heat.
    My website with battery and charger information: lygte-info.
    More than 1000 reviews of batteries, charges and other stuff.
    Compare 18650 LiIon batteries or smaller (RCR123, 16340, 14500, 10450) LiIon batteries.

  30. #30
    Flashaholic* RI Chevy's Avatar
    Join Date
    Aug 2011
    Location
    Ocean State
    Posts
    3,543

    Default Re: Rewrapping a battery

    Try and use a little flame on it. Like a lighter.

Page 1 of 2 12 LastLast

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •