Making a dummy cell

[degarb]

What is best way to make a light dummy cell with wires soldered and glued to negative side. Aluminum foil would be too prone to malform over time on this project.

I was wondering if I could make a dummy battery out of old Lithium cell. Will it corrode over time like acid battery, or flammable if I drill and solder into it?

 

[Chodes]

My preferred method:
Use some blank circuit board. Usually easy to find offcuts cheap.
It's a great material to work with, the copper comes in handy too..
I make round discs using a drill press and sandpaper. With a bit of care it's easy to make perfect fit in Mag bodies.
I've etched off the all the copper on 2 of these , left some in the centre on 2.

For a Mag C or D spacer , you can use bare board with a bolt of suitable length between the 2 discs. Use a washer big enough on the spring end.

Alternate - leave more copper on 1 disc for the spring end, spring can make contact with the copper instead of washer.

Adjust at anytime with a different length bolt or make it sol spring goes over nut so you can adjust length.

I make these 10 at a time for custom switches , spacers , "bulkheads" in tailcap Mags , tailcap switches , heat shields.....

 

[Chodes]

This switch is basically a spacer with switch added. Showing other construction methods.

This disc is just a press fit in the tailcap. It was just a temporary , but so far I've used it for months and it does not spin in the tailcap (would twist the wires to the switch) Just showing how easy to make these really good fit.

 

[alpg88]

i had to make a dummy d cell once, i used mettal rod the same lenght as d cell, packing foam circles, and hot glue.

 

[lctorana]

I made a dummy AA Cell using a thick copper nail inside a piece of 14mm dowel.

Don't ask me to post pictures, because I subsequently lost it...

 

[VidPro]

same here, find a long bolt, cut it to length put some insulation around it, then be a bit carefull about how it JAMMS into the bottom or the top of the other cell item. like it can be a bit shorter, or butt up against the other cell with a nice lot of materials (shoulder) of the insulator materials.

dont EVER never use an old cell of ANY type, that is just asking for problems of many sorts, dead lithium cells especially.

hunk of dowel, wire and 2 tacks :-) plastic tube and a spring, and washers, a pipe , whatever it takes,even if you gutted a battery to try and use as a frame, you will still end up with the same basic parts you can find in any trashcan without the toxic crap inside :-) broom stick cut to length, drill a hole down the center, shove a hunk of metal down it, tightly rolled foil and duct tape.