This is a tutorial i wrote up to make a 9.6 volt battery pack with the standard AA battery holder.

HOW TO MAKE 8 CELL AA BATTERY PACKS!
I am in no way responsible for any damages or injuries to anyone who tries this guide. It is only a guide for people who may want to try it.

This is an idea i have seen once or twice but never really knew how to tackle it.


The first step for you is to gather some equipment

You will need

8x AA batteries, NIMH rechargeable. The more capacity the more runtime. (I used 2500mah for this)
A soldering Iron (decent one, about 50watts)
A standard Mini Inferno AA Battery Holder
A connector plug for the end of the battery

The first step is to look at the battery holder. The main trick here is to follow the basic pattern that the batteries currently have. Which is POSITIVE TO NEGATIVE, NEGATIVE TO POSITIVE.

The task we are doing is adding the cells onto were the current connector wires go to. The first task is to remove the tabs that the RED and BLACK wires are connected to as below:



Once this tab is pushed out, its just a matter of desoldering the wire and you will be left with a tab. Do the same for the negative wire as well.

The next job is to get one of your AA batteries into a Vice (or something to hold it securely).
The task at hand is to apply the soldering iron to the END tab of the POSITIVE side and coat it with some solder. It will usually take about 2-3 seconds for the solder itself to bond.