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CREATED BYSTEVE MASON

YOU MAY USE OR MODIFY THIS GUIDE TO YOUR NEEDS. THE INTENT OF THIS GUIDE IS TO HELP OTHERS SO FEEL FREE TO

DISTRIBUTE FREELY. 11 MAR 2009

REQUIRED SKILLSYou will need to have some mechanical aptitude and a ability to solder electrical parts together in order to use this guide successfully. If you don’t possibly someone you know may and could help you or better yet do the rebuild for you. If you do not have the required skills it is very possible you could break the battery casing, contact assembly, and/or even worst yet start a fire by shorting the batteries out so be careful and don’t attempt this unless you have the skills required.

DISCLAIMERBy writing this guide I take no responsibility for any damages you may occur in the process of rebuilding your batter pack(s). You must attempt this at your own risk and take responsibility for any damages that may occur. The batteries you are replacing and using are capable of starting a fire or even explode if shorted so you must be very careful when working with these materials.

GUIDE INTENTThis guide is specifically written for the DeWALT 14.4v XR battery packs but can be used for the new 14.4v packs as well as 12v & 18v packs. If used for battery packs other then 14.4v you will have to make your own template for the battery layout and the quantity of batteries used for each pack will change as well, obviously. The physical dimensions of the battery might also change so if you are rebuilding a battery pack outside of this scope be sure to remove and measure your batteries to guarantee the replacements fit. You may also need to verify voltage and current requirements so do some home work if you find yourself in this situation.

For most DeWALT battery packs you will be able to use 1.2v NiCD Sub C batteries that are 43x23mm in dimension and have current capacities of 1200 to 2400mAh, the higher you can get the better as long as they physically fit of course. Since the Sub C’s are daisy chained and you are using 1.2v batteries the quantities for each battery pack should be as follows for a give voltage.

For this example we will take a 18v battery pack that uses 1.2v batteries to determine the quantity required to rebuild the old battery pack.i.e., 18 / 1.2 = 15

12v Battery packs (10 qty) per pack14.4v Battery packs (12 qty) per pack18v Battery packs (15 qty) per pack

Here are most of the things you’ll need to rebuild your battery packs. There is two items missing in this picture, a medium slot screw driver & electrical tape or some type of cellophane wrap.

To replace two batteries it would cost around $130 but to rebuild them here it was $42 including shipping. I bought the batteries from All-Batteries which has a website and a eBay store, the eBay auction was cheaper by almost $20. It is very important to get the proper size & current capable battery. Also you can get batteries with or without tabs, I would suggest getting them with tabs. If you have a choice get just tabs on the positive side of the battery, then you won’t have to remove the negative pole side tab later on in this procedure.

It is also important to have a 25 to 50 watt soldering iron with a pretty hefty sized tip although a small tip can be used as long as your iron will get hot enough. In this procedure I set my iron at 850°F in order to get good solder flow when soldering the tabs to the battery.

All-Batterieshttp://www.all-battery.com/eBay Storehttp://stores.ebay.com/All-Battery-Center

Battery Junctionhttp://www.batteryjunction.com/

OVERVIEW

● Soldering iron (25 to 50 Watts) *Hotter is preferred● Electrical Soldering Flux (NOT Pluming Flux!)● Resin Core Electrical Solder ~(60/40)● Isopropyl Alcohol 91% (NOT 70%)● Que Tips● Jewelers Slot Screw Driver (good size)● Needle Nose Pliers (small)● Side Cutter (medium size)● Knife (Putty or semi sharp kitchen knife)● Torx Driver (T10)● Slot Screw Driver (medium)● Electrical Tape or Cellophane wrap● Replacement Batteries, Sub C NiCd 43x23mm 1.2v● Battery Rebuild Template sheet● DeWalt XR Battery Pack(s)

TOOLS USED

STEP #1Get batteries out and remove clear cellophane wrap.

STEP #2Using the needle nose pliers carefully peel off the negative side tab from all batteries. This is the flat side of the battery not the side with the nipple on it.

We only need one tab per battery as they all will be daisy chained together later on in this procedure.

Push down and flatten material left from removal of tab with small screw driver as seen below.

STEP #3Straighten out the remaining tabs found on the posative side of the battery.

STEP #4Slide shrink tube off tab slightly and trim off about a ¼”, slide tube back up snug to positive nipple as shown. Do this for all tabs to prepare them to be soldered later on.

STEP #5Remove the 5 (T10) Torx screws and detach top cover of battery pack.

STEP #6Using the medium size slot screw driver carefully slide it between the case and battery pack at the points shown with the case upside down allowing gravity to aid in dropping battery pack out of case.

STEP #7Remove the post battery tab from the rest of the battery pack using the needle nose plier.

Post battery tab removed from the rest of the battery pack.

STEP #8Now lets remove the plastic assembly retaining the battery contacts using the jeweler screw driver. Flatten copper battery contact after removal if bent up during process.IMPORTANT: Be very careful not to break the plastic casing which retains the contacts and snuggly fits to the post battery.

STEP #9Remove foam pad from bottom of post battery trying to keep adhesive on foam pad as it will be used again when we build the new battery pack.

STEP #10With post battery free bend tab vertically and carefully remove protective sleeve. Put this sleeve aside as we will use this again when we rebuild the new battery pack.

STEP #11Very carefully we need to remove the the top cardboard protective pad from the battery pack. Use the semi sharp knife to carefully peel the gasket from the battery assembly. You will also need to be careful not to short the battery pack out while doing this as it will spark and weld the blade of the knife you are using. Take you time removing this also once again trying to keep as much adhesive on it as we will use it when building the new assembly.

STEP #12Flip the battery pack over and do the same to the bottom protective pad again being very carefully not to short the battery pack out while doing this and keeping as much adhesive on it as well since we will use it when building the new assembly.

STEP #13Get you soldering iron out and remove the white wire from the battery tab. The contact assembly will be used again so put it aside for now.

STEP #14One by one remove batteries from the chain keeping the tab connected to the positive post but removing it from the flat negative side. Bend all battery tabs vertically once removed from the pack.

STEP #15Carefully remove all of the protective sleeves and save for the new assembly. They may come off easily but some may have some adhesive residue left from the protective pad we removed earlier. Use your knife to go between the battery case and sleeve to free the sleeve from the battery case. Even though the replacement batteries have a plastic insulator it may get damaged some when re-soldering the new assembly so for protection reasons we will reuse these protective sleeves.

STEP #16Now that you have all of the old batteries stripped from their protective sleeves you can prepare them to be recycled.

Notice: all sleeves are the same hight except the sleeve for the post battery which is shorter then the rest.

STEP #17Flip all of the tabs vertically and slide the protective sleeves fully over the new batteries.

STEP #18Flip all of the tabs back to the horizontal position and the short sleeved post battery to be separated to the side keeping the rest of the batteries together..

STEP #19Lay all of the batteries except the post battery out in a line in front of you with the negative side up (flat side) and dab the center of each battery with resin flux.

STEP #20Grab your iron and resin core solder and start soldering small dabs of solder to the centers of the batteries. Make sure not to put too much solder on and to heat it up enough to acquire good solder flow, no balls of solder. In this case less is better then more.

STEP #21Your solders should look like this if you have done them proper. We will also have to clean off all that resin ASAP as it get more difficult to remove with time.

STEP #22Now get your Isopropyl alcohol & Q-Tips out and start cleaning off all of the resin residual off the batteries. When your done they should be pretty clean and ready for the next step.

STEP #23Lay the battery template out in front of you with the Top Side layout closest to you, as shown in the picture here.

STEP #24We are ready to solder the first two batteries together and we will start from the Bottom Side layout. Lay the first two battery on the template as shown.

IMPORTANT!!NOTE: The tab that is to be soldered next is located to the next batteries position in the chain even though that battery has not been introduced yet. We need to have the next tab located properly before soldering the pairs together.

Tab MUST be orientated properly before soldering the two batteries together!

STEP #25Now that we are oriented properly hold the batteries and solder the tab down to the opposing battery. You’ll want to use the medium size slot screw driver to hold the metal tab down securing the solder joint until cool otherwise tab will pop away.

STEP #26Now being careful flip the two batteries you just soldered to the first pair location on the Top Side layout and add the third battery to its position with tab oriented properly. Solder when ready.

Tab oriented proper.

STEP #27Flip the three batteries you just soldered to the Bottom Side layout and add the forth battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #28Flip the four batteries you just soldered to the Top Side layout now and add the fifth battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #29Flip the five batteries you just soldered to the Bottom Side layout and add the sixth battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #30Flip the six batteries you just soldered to the Top Side layout now and add the seventh battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #31Flip the seven batteries you just soldered to the Bottom Side layout and add the eighth battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #32Flip the eight batteries you just soldered to the Top Side layout now and add the ninth battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #33Flip the nine batteries you just soldered to the Bottom Side layout and add the tenth battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #34Flip the ten batteries you just soldered to the Top Side layout now and add the eleventh battery to its proper position with tab oriented correctly. Secure and solder when ready holding tab down until solder has cooled.

STEP #35As you can see the grouping is very good we are well within the template dimensions.

Now we just need to add the Last battery to the eleven pack we’ve just assembled.

STEP #36First lay the battery on the template in the location it will be when it is setting on top of the eleven pack we just assembled with the tab to the front and place the contact assembly with the copper tab forward. With the plastic assembly snug on top of the battery solder the copper tab to the top of the battery. You may want to use some flux as it will make soldering much easier. Clean off the flux if you choose to use it.

STEP #37Split the battery pack on the left side and bend the tab upward along side the battery.

Copper tab soldered

STEP #38Tin the tab with solder so that we can attach the white wire from the post assembly.

Tin with solder

STEP #39Solder the white wire from the post assembly to the lower assembly battery tab.

STEP #40Bring lower assembly back together and place post battery on top of pack. You will need to be careful here as the top battery can short out on the bottom pack. Now with everything in place solder the last tab to the top of the lower pack.

STEP #41Take the needle nose pliers and bend the bottom tab of the post battery forward creating a ¼” step raising the battery upward.

STEP #42Affix the foam spacer underneath the battery contact. This will space the battery properly and insulate any contact with the battery pack below.

STEP #43Lay the top and bottom protective pads with the adhesive up in front of you.

STEP #44Lay the pack assembly on its side and adhere the bottom protective pad to it.

STEP #45Take and tightly wrap one piece of electrical tape around the battery pack drawing the batteries in as tight as you can get them and only over lapping the tape slightly. We don’t want to build up the diameter of the battery assembly as it will make it difficult to get back in its casing.

STEP #46Pull the foam spacer back out temporarily and cut a small square off the front of the top pad to prevent the front battery tab from interfering.

STEP #47Slip the top protective pad into place making sure the white wire slides through the pad slit and press down on the pad when in place to adhere to the battery pack. Also slide the foam spacer underneath the post battery. If you have rubber or silicon glue you may want to glue it to the bottom of the battery as the foam adhesive probably isn’t very sticky anymore.

STEP #48Were are in great shape now the battery pack fits perfictly over our template and is pretty solid. It is time to get the bottom case and start putting the new battery pack into it.

STEP #49Now let’s slip the battery pack into the bottom case. You may need to compress the battery pack in several places to get the pack to slide into the bottom case. Also be aware that the electrical tape will hold up on four of the five screw posts in the bottom case. Go to the next step before trying to force the battery pack down futher then the tape line.

STEP #50You’ll have to push the tape in at each of the four screw posts found in the bottom cover in order to get the batter pack pushed down to the bottom of the bottom case otherwise you won’t get the top cover screwed down.

STEP #51With battery pack fully inserted it is now time to put the case top cover back on.

STEP #52Place top cover onto batter pack and make sure to get contact assembly lined up with rectangular hole at top of post. Slowly force cover down but don’t over stress top cover because you could break it.

STEP #53You can see the top cover doesn’t fully seat so put the center screw in first helping the cover seat as you screw down the T10 Torx screw.

Once you get that screw in tight proceed with the last four helping the screws draw down the top cover.

STEP #54Congratulations we are all done the top cover is seated and secured the battery pack is ready for its first charge.