Battery pack repair tips

Very many battery packs are built using standard size cells inside the plastic package. When cells go bad, it is often possible to replace the cells with new one either as DIY project or have some repair company to do that. Usually my option one is to find replacement battery for devices, and if it is unavailable or terribly expensive, consider putting in new cells. Building the new battery pack needs some knowledge and right tools (small spot welder and/or soldering iron).

Cordless Drill Battery Pack Rebuild for $20 or Repair for $0: Nicd Battery Pack Rebuild

Total cost at time of rebuild was $22.54 to rebuild the entire 14.4V Pack with better than original batteries.

How To Rebuild Your Old Rechargeable Battery Packs with new ones. CHEAP!

Repacking Makita 18v Lithium battery with New Cells (Save $$$’s)

Warning: Trying to fix battery without knowledge to do it right can lead to more damaged battery pack, damaged device being powered and possibly start a fire

10 Comments

  1. Tomi Engdahl says:

    Charging NiMH cells – smart vs dumb chargers
    https://www.youtube.com/watch?v=5yFwhWeqyq4

    A brief summary of NiMH cells and their charging techniques, and why smart chargers are usually not so smart.

    This video is especially handy because Clive has also briefly discussed different battery technologies from Ni-Cad, Ni-MH, Li-Ion, and Li-Fe-Po . I hope the search algorithm recognises this as well, so as to direct more viewers to this helpfully informative video – and the channel.

    Reply
  2. Tomi Engdahl says:

    Are AA NiMH Batteries obsolete? Here is everything you need to know about them!
    https://www.youtube.com/watch?v=5B1sX7p5xXI

    EEVblog #35 2of2 – NiMH and NiCd Battery Charging Tutorial
    https://www.youtube.com/watch?v=_ROhH9EkhtU

    Reply
  3. Tomi Engdahl says:

    Battery Type Comparison || Lead Acid VS NiMH VS Li-Ion VS LiPo
    https://www.youtube.com/watch?v=LqgP16JQ24I

    In this VS episode I will compare the gravimetric and volumetric energy density and the price of lead acid, NiMH, Li-Ion and LiPo batteries with one another. I will also talk about how dangerous each battery type can be and what kind of battery you should get for your next project.

    Reply
  4. Tomi Engdahl says:

    Make your own Li-Ion Battery Pack
    https://www.youtube.com/watch?v=hwhqn4BmC2I

    In this project I will show you how to combine common 18650 Li-Ion batteries in order to create a battery pack that features a higher voltage, a bigger capacity and most importantly useful safety measures. These can prevent an overcharge, overdischarge and even a short circuit of the batteries.

    More project information (parts list, pictures,….) on Instructables:
    https://www.instructables.com/Make-Your-Own-Li-Ion-Battery-Pack/

    Reply
  5. Tomi Engdahl says:

    HACKED!: Old laptop battery becomes a Power bank
    https://www.youtube.com/watch?v=UjG2QGOC4aA

    In this episode of HACKED! I will convert a battery from an old laptop into a power bank which can charge my phone 4 to 5 times with a single charge.

    Reply
  6. Tomi Engdahl says:

    DIY Laptop PowerBank (battery pack to charge your laptop on the go)
    https://www.youtube.com/watch?v=ZQjazsiyr8s

    In this project I will show you how to create a Laptop PowerBank. It mainly consists of a Li-Ion battery pack and one buck and boost converter. This way the PowerBank can get charged up through the Laptop power supply and aftewards charge up the Laptop directly to give it an additional run time of 3 hours. Let’s get started!

    Reply
  7. Tomi Engdahl says:

    Building a USB Type-C PD Powerbank the Super Simple Way || Testing an Aliexpress PCB!
    https://www.youtube.com/watch?v=yEbbhTw0kno

    In this small project I will show you how to create a DIY USB Type-C PD powerbank the super simple way. To do that I will firstly test a powerbank PCB based around the IP5328P IC I got from Aliexpress. The measurements will show us how suitable the PCB is for creating a DIY powerbank. Afterwards I will then show you how I created a Li-Ion battery pack and a custom 3D printed enclosure before I will put all the components together to form the powerbank. Let’s get started!

    https://www.instructables.com/Building-a-USB-Type-C-PD-Powerbank-the-Super-Simpl/

    Reply
  8. Tomi Engdahl says:

    When Battery Rebuilds Go Wrong: Understanding BMSs, Spot Welders, And Safety
    https://hackaday.com/2022/02/16/when-battery-rebuilds-go-wrong-understanding-bmss-spot-welders-and-safety/

    Batteries are amazing. Batteries are horrible. Batteries are a necessary evil in today’s world of portable everything. If you’re reading this sentence, even if it’s not on a mobile device, somewhere there is a battery involved. They’re that ubiquitous. There’s another thing batteries are: Expensive! And at $350 each for a specialized battery, [Linus] of Linus Tech Tips decided to take battery repair into his own hands.

    Rather than do a quick how-to video about putting new cells in an old enclosure, [Linus] does a deep dive into the equipment, skills, and safety measures needed when dealing with Lithium Ion cells. And if you watch the video through, you’ll even get to see those safety measures put to good use!

    This should be illegal… Battery Repair Blocking
    https://www.youtube.com/watch?v=Mkum7G-0vWg

    Reply

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