Custom Battery packs

[Aircraft800]

Does anyone have a tutorial or video showing how to make custom battery packs from loose cells?

I've noticed that Mad Maxabeam and cmacclel all use these cool looking shrink wrapped packs, but found no info on how to make them or charge them. (I don't want to bother them with a PM, I'm not that important) I've tried the search function and have found little.


Are the custom packs sold here, or any external links?

Thanks for all of the help.

 

[defusion]

http://www.cheapbatterypacks.com/ makes custom packs (mostly for RC use).
Ofcourse you could make it yourself with loose cells and some solder and wires aswell.

 

[SilverFox]

Hello Aircraft,

You may find this thread interesting.

Tom

 

[LuxLuthor]

That is a classic video which I have already used. I have taken apart all of MM's battery packs, and now collected all the parts to reproduce them in all the versions I have seen. Look at some of the pix I took towards the bottom (Post #87) of this thread with hi-res photos.

Maybe I'll make a thread just about making them sometime.

 

[Aircraft800]

That is a classic video which I have already used. I have taken apart all of MM's battery packs, and now collected all the parts to reproduce them in all the versions I have seen. Look at some of the pix I took towards the bottom (Post #87) of this thread with hi-res photos.

Maybe I'll make a thread just about making them sometime.

@SilverFox

Great Video! That makes it look easy, I just need to locate some tools now!!

@LuxLuthor

Please do sometime!! Those are some awesome pics! Share that knowledge!

I love to see the custom packs the pro's use, and I just need to see the technique and tools needed and I can build my own. I'd also like to offer that service to friends and rebuild some Makita battery packs I have.

Thanks LuxLuthor

 

[LuxLuthor]

This note from CheapBatteryPacks.com was surprising when I asked them about when they will have some high current, quality AA size batteries back in stock if someone wants to make a pack.

"IB2000's got too expensive. Factory is no longer offering CBP1650's. Others we have tested are not that great.

4/5A 2000 cells would be the way to go for true high output"
​

So now it looks more important to master those battery pack soldering skills. I wonder what Tom would recommend is the best AA battery for 1185 type high current mods, even if we have to solder our own.

 

[SilverFox]

Hello LuxLuthor,

Check out the Titanium Power Max 1800 mAh cells from Amondotech.

Tom

 

[Aircraft800]

Titanium Power Max 1800 mAh cells from Amondotech look HOT!
High discharge capability at 10C rate. Can discharge at 18 AMP.
IB2000 (SUMIB2000AA) look resonable at some RC sites, $12.99 for a 4 pack.

(some links included) ^^^^^

These may be a good alternative for someone like me who doesn't have access to machines to tri-bore the body my m@g

 

[LuxLuthor]

Sweetness! :twothumbs

 

[Bullzeyebill]

The new Titanium 1800's look like they may have a high self discharge rate if they can sustain 180mA's overdischarge for one year. My CBP1650's self discharge fairly fast, particularly when compared to my Kodak AA low self discharge batteries. I know that there is a trade off here, high load discharge rate up to 18A's, but it is nice to have your lite work when its been sitting for a month or so.

Bill

 

[SilverFox]

Hello Bill,

I have not noticed any cases of high self discharge rates with these cells. They seem to have a lower self discharge rate than higher capacity cells, but they are not as low as the Eneloop cells.

Tom

 

[Aircraft800]

Hello Bill,

I have not noticed any cases of high self discharge rates with these cells. They seem to have a lower self discharge rate than higher capacity cells, but they are not as low as the Eneloop cells.

Tom

Just a quick question then,

I use my flashlight on a daily basis, I work nites. Is there a tradeoff, long shelf-life, cycles, and duration? I'd like to get a long runtime so it stears me to a high mAh battery, but the high mAh have a shorter life just over 500 cycles, that's why I was looking at the high output cells. I don't need the long shelf life like the eneloops, but want the long runtime. I plan on using 12 AA cells series/parallel (7.2v to run a WA1111) to have a long, brite run.

Anyone have some input on a battery selection that meets my needs? Should I only charge NiMh when they are nearly dead to save on cycles, or charge everyday?

Thanks for the help everyone here! This thread has really grown, and I hope to get a tutoral on building custom cells.

 

[SilverFox]

Hello Aircraft,

High current cells are able to maintain higher voltages under load. In a direct driven light, this results in a brighter beam. You pay for this in reduced runtime.

High capacity cells give you longer runtime, but can't hold as high a voltage under load.

Lower capacity cells seem to be capable of longer cycle life.

It is a juggling act. You pick what is important to you and go with it.

Depth of discharge does influence cycle life. You are better off not running the batteries completely empty every cycle. Running them down to around 0.9 volts per cell every 25 - 50 cycles keeps them "vibrant," but it is not necessary to do this every time.

Tom

 

[LuxLuthor]

A real simple way to illustrate what Tom said in the example of these Titanium Power Max 1800 mAh cells is if you are using them with a bright bulb that likes lots of "juice," you are gonna burn brighter for a shorter run time, but they should have more total charge cycles if you take care of them.

Or you go for a weaker bulb lumen output, but longer run time with a higher mAh rated battery from the top performers in his table at the top of this thread....like the Sanyo 2700's...and maybe have fewer charge cycles lifespan.

I'm assuming like the Titanium 2400's I got, these 1800's need several cycles of charge/discharge & a 0.1C forming charge to get them to their optimal performance.

 

[Aircraft800]

I gathered some of the item's needed to make custom battery packs, I'd like to share so others looking for the tools needed can easily find them.

a) Mega Hammerhead Solder Tip

b) Mega Acculine 200 battery solder jig

c) Great Tutoral from Glen Peden's LOGO Mania

d) Andrew Willetts Video Tutoral

or HERE

(I'll try to keep this updated, and feel free to help out and ad necessary items)

 

[LuxLuthor]

Thanks for those links. There is a nice 60W with hammer head iron at CheapBatteryPacks.com here for $20, but their HammerHead tip alone is $1.70 more. That last link also has the zinc flux and solder to use with aluminum which actually works. I was amazed.

I wonder if their jig is magnetized to avoid the cells tumbling forward when you lift them.

Edit: Yeah I found this other link that says it is. Why the hell don't they say that on the link you posted??? Anyway, I ordered one.

 

[Aircraft800]

Nice Links LuxLuthor! I like that 60W Hammer $20!!!

Thanks for the help!

(Maybe we should have started a new thread with just Battery Pack Building, and eliminated all of the stupid battery questions I had earlier, all have been covered in the links you provided )

 

[LuxLuthor]

LOL...yeah, but its all good. The HH tip from CBP is solid copper and has the exact same (about 8mm) flat ending on both sides, not slightly sloped on the one side like your link.

Remember also to get flat top batteries like this one from Amondo so they solder better.