Tutorial - 9.6 VOLT AA BATTERY PACK!!!

[Lord_Inferno]

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.

[Lord_Inferno]

Once this is done apply some solder to the end of a piece of wire (around the same thickness as what is joining the 2 saddle pieces together. I did mine about 1 inch (or 3-4cm in metric). The next task is to solder the wire onto the tab. Once its done it should look like this:



Now you will need to do the same thing but with a different piece of wire this time to the Negative side. Remember to strip both sides of the wire, it will be much easier to do than when the battery is soldered.

The next task is to take your AA battery which had the negative side soldered on and the Tab we removed from the actual Saddle pack.

Once you solder the other side of the wire to the tab, its just a matter of pushing the tab back in. When looking from the front of the Buggy, this saddle is the one to the RIGHT.

[Lord_Inferno]

Here is a close up of the negative wire connected.



You will have to do the same thing with the Positive side and solder the wire to the tab.

The final step is to get your connector (you can still use your standard wire which we removed from the saddle) and to repeat the steps of soldering the wires onto the actual cells.



here is the final product


How does it go?
It doesn't have the acceleration that the nimh have, but the top speed and overal performance is MUCH better than the 7.2 volt pack.
Runtime though is much better

[SteveR1960]

Very nice! I have stickied it.

[Lord_Inferno]

Thanks for that
I love these things and enjoy mucking around with them heaps.
I'm working on a web site at the moment too which is
http://miniinferno.zexxo.net

Its only a personal site!

[008]

Here is a close up of the negative wire connected.



You will have to do the same thing with the Positive side and solder the wire to the tab.

The final step is to get your connector (you can still use your standard wire which we removed from the saddle) and to repeat the steps of soldering the wires onto the actual cells.



here is the final product


How does it go?
It doesn't have the acceleration that the nimh have, but the top speed and overal performance is MUCH better than the 7.2 volt pack.
Runtime though is much better

Hey ! that is pretty cool. I did the same thing but instead of going direct solder to the batt I went to Radio Shack and purchased 2 AA single batt holder's and then soldered the wires correctly and Bamm! There you go. I have to dissagree with you on the speed, my mini inferno is much faster and im using the stock motor and of coarse ball bearings.Your speed will also depend on what type of batteries you use , Im using Enigizer 2500mah batt , all nickle metal battries are not the same quality nor are they made equal, the better the batt , the more power and speed.

[rnrry]

As I am not a writer what I am going to does it this. I am going to touch on a few key points to explain a bit about battery packs so you will have a general idea as to what type of battery pack you may need or how many cells you will require to rebuild your battery pack.
Lets use a 9.6 volt battery pack as an example. Lets say you have a battery pack that is 9.6 volts and you want to replace it. Great lets do that. First off I want to inform you that any 9.6 volt battery pack will do the job of another however I am sure you will have size restraints. A 9.6 volt battery pack consist of 8 individual batteries of 1.2 volt each.
Different size battery packs use different size cells. There are many different size cells such as sub c mainly for drills 2/3 a, 2/3 aa, aa cells and many others.
Before you do anything remove the batteries from your battery pack and take the measurements that way when you call me I can really help you out without playing guessing games.
Lets touch on the voltage aspect of the pack. Below you will see a list of voltages and how many cells you will require to rebuild them.
2.4 volt 2 cells of 1.2 volt
3.6 volt 3 cells of 1.2 volt or 1 lithium ion cell
4.8 volt 4 cells of 1.2 volt
6 volt 5 cells of 1.2 volt
7.2 volt 2 cells of 1.2 volts
8.4 volts 7 cells of 1.2 volts
I hope you see what I mean as to how a battery packs is configured.
It may be possible that you have a 3.7 volt 7.4 volt 11.1 volt or 14.4 volt battery pack which would have lithium ion cells. Lithium ion cells are different from nicad or nimh cells.