Need some help guys

[mdhammack]

I need a little help making a battery pack. I am trying to solder up a 6AA pack to fit in a 2d maglite. I can get individual beads to stick to battery ends, but can't get the two batteries to stick together. I am putting a bead on each battery then pressing them together and placing the iron inbetween them and the solder never seems to melt. Maybe I need a stronger iron, I am running a 40 watt, just cleaned the tip, it's snug, don't know what else to do so I'm turning to you guys for help.

Thanks in advance!

David

 

[VidPro]

that'll work i seen it done before, just a pain and it might heat things up more than nessisary. plus the minor straight alignment issues when the connection is solidified.
your this far now, meaning you now have the ends tinned.
tin some "tabs" of easy to solder metal, like nickle plated, or copper, or just use use a copper wire, and solder it on each end, THEN fold the batteries up into the pack, it actually takes less space than the blob does.

a nice fat copper wire can be blacksmithed on a Anvil with a hammer a Lot easier than it looks, so you can take a nice copper wire of say 4-10 guage, and smack it a few times and have a nice copper tab. then you can solder each side in the open, then fold it up together.

tin any wire or tab you use before assembly , because you dont want to take to long with the heat, or you will heat up the internals of the cell.

people on THESE actual forums, make some of the best AA holders in existance, and the advantages of that is you can take stuff out and check it, and charge and discharge as singles.

 

[mdhammack]

didn't think about that....I'll give it a shot.

Thanks

 

[mdhammack]

just finished up with your copper wire method....got 8.3 volts on a rested pack! This will do for now, but I think I am going to spring for some more fivemega holders.