Homebrew AA Battery Pack?

[Tony.RI]

I have a completely dead NTN4595C Saber Battery, and I've been thinking of making a AA battery pack out of it. I'm only planning on using rechargeables, so 6 should work nicely. How should I go about opening the case?

[kf4sqb]

The best way I know of is a Dremel tool with a cut-off wheel, a steady hand, and a lot of patience. These packs are "ultrasonically welded", which means, more or less, melted together. They are about as close to "molded in place" as you can get without actually being molded in place.

[toyradios]

I was thinking of doing the same thing.

Please post some pictures when its completed.

Bill

[Tony.RI]

Well, I did it today! After a couple hours of cutting, I got the pack apart. I tried soldering directly to the contacts, but of course it deformed the plastic there. I then tried hot glue which didn't work, and then the last solution I devised, which sometimes works when pressure is applied. It sure isn't pretty, but it's a proof of concept. I'm thinking of using nuts, bolts, and spacers as a more permanent fix.























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