After reading an article in last months Back Home Magazine about re-using dead drill batteries, I decided to try it for myself. Cordless drills are the great, but if you are unable to recharge them due to a loss of power or you are too far from an electrical outlet, you're out of luck.
Taking a junk battery that no longer works, I've given it a cord, perfect for attaching to your 4wheeler or car battery.
This battery no longer works. It's worn out and can't hold a charge.
Start by removing the 6 screws that hold the case together.
The case comes apart with minimal prying.
Take a pair of dykes and cut the Capacitor off of the batteries.
I left the sensor alone. I don't know what removing it will do.
Drill a hole in the rear of the case, large enough for the cord to fit through.
For the cord I used 25' of 12 gauge 2 conductor leftover from work.
You could also use and old extension cord or an old vacuum cord.
Due to voltage drop, I don't recommend using anything longer than 25'.
Make sure to do a good job soldering the cord. Once this is assembled, there's no repairing it.
I taped the entire assembly together to prevent the cord from moving and snapping.
Insert the assembly back into the case. Make sure it sits flush.
If not, the terminals won't make a good connection in the drill.
Stand the case face down and support it well. It's going to sit in place for the next 24 hours.
Before sliding the cord through the hole in the case, tie a knot in it.
This will prevent the cord from putting to much stress on the assembly.
To prevent the assembly from falling down into the case, we need to hold it in place with epoxy.
I used almost the whole tube filling in around the assembly.
Make sure BEFORE soldering the clamps onto the cord end that you slide the rubber handles down the cord first.
I got ahead of myself and soldered the clamps first. :-/
The Finished Project!http://www.youtube.com/watch?v=SVyZRBgbBJQ&feature=player_embedded#