I have a lot of experience DIY tweeking and working with electric circuits from my involvement in car audio, RC cars, and guitar tube amps. I was very careful and cautious, yet I still managed to screw up. I work on these outside on my brick patio so if the cells do flame up the flames don't ignite to anything of value (except possibly me
). I can't imagine the average joe attempting this kind of a mod.
I was cutting a segment of wire to free up a cell and as my cutters were cutting through the wire a sharp backside edge of my wire cuter sliced through the cell heat shrink and shorted + to -. It sparked, smoked and melted the heatshrink for a moment. I have since dremel'd my wire cutters to remove all sharp edges and burs.
Second incident occur'd when I tried to cut through one of the metal strips with my wire cutter. I was not careful in observing the circuit and had not noticed there was a wire behind/beneath the metal strip. When I cut the strip I shorted the wire and strip!!! WOOOHOOO!!! the wire welded to the strip and became a fuse-link between + and -. It turned red hot and lit the insulation, tape and adhesive on fire. I keep a wet towel at my side during the procedure, so I ousted the flames easily.
"You don't necessarily need to bother with that. Just cut the tabs at the cell terminals and the circuit is de-energised."
Easy to do in theory, not so easy in the real world. The way the packs are assembled, taped and glued together you simply can't access those points in the circuit without pulling the cells apart and opening things up far enough to get a wire cutter "in there". Thats partially how I made the two mistakes listed above... trying to shove my wire cutter in between and beneath tight areas to access the points to disconnect the cells.
I get the packs from the recycle program at work.... one mans trash...
The intent of my posting is not to discourage the idea of modding / replacing / salvaging ells, but more to alert CPFers who do take on such a project. There are safety concerns and an element of risk in doing this. The video dismissed the safety concerns all together and made it look no more dangerous than reloading AAs into a VCR remote. Furthermore, the pack used for the demo is unusually well laid out, with cells perfectly side by side.... very low risk of + and - contacts being close to each other. I took apart a toshiba pack just like that, for its 17670 cells and it was relatively easy.