Battery Adapter file exchange.

[Nomad]

Just for ideas / reference

I've been looking for batteries for a slightly older Dewalt and found you can get off-the-shelf adaptors for £16 to fit Dewalt Li-On batteries onto Dewalt Nicad tools.
Love the idea of this thread but if a ready made adaptor is available cheaply it's another option to consider.

https://www.amazon.co.uk/dp/B082YVWQS8?ref_=cm_sw_r_apin_dp_56SX4F2KYTVJJHJK52KJ

 

[Onoff]

Love the idea of this thread but if a ready made adaptor is available cheaply it's another option to consider.

https://www.amazon.co.uk/dp/B082YVWQS8?ref_=cm_sw_r_apin_dp_56SX4F2KYTVJJHJK52KJ

Erm...I think you're forgetting what forum you're on! It's all about the journey as much as the destination!

 

[Anguz]

anyone got a drawing that i can edit in fusion, that fits a dewalt xr battery pack ?, and does anyone know for certain if the battery protection is in the pack or the tool ?

 

[Onoff]

An elderly neighbour of my M&Ds is a big WORX fan. Drills, strimmer even lawnmower I think. Ex army engineer, I think he's 80 odd but can do it all. The type who made his own lathe and compressor. He likes WORX, it does for his needs so there'll be no steering him onto another platform. Helped me out no end as a kid. Or as he once put it "All you've got to keep is your car and your dick! There's a garage full of tools now get in there and do those brakes!"
This after following me home one day 40 years ago and seeing the Capri brake to one side. Not helped by the fact I'd had the pads sat on the parcel shelf in plain view for weeks. Happy days!

I digress. He also has an old, perfect condition Makita 18V drill that came with x3 NiCads. All long dead. He wants to use WORX batteries on it.

Plan is to retain the original, (grey) tower. First problem is recreating the profile. This, from scratch is a pig to do as I found doing the old style DeWalt, tower one. Then I drew around the original, scanned as a DXF etc.

This time my lad took somebody else's attempt at recreating the (red) battery case on Thingiverse or similar. In Fusion he broke it down and sent me a DXF of the profile. He said the model was "messy" but fair play to the originator, it's a pig. The Thingiverse model then wasn't symmetrical which if nothing else bugs me. The original cases are I guess injection moulded so there's some inaccuracies there too. I thus split it about the centreline and mirrored the resultant half so symmetrical. Two attempts at a template below, it looks better than it fits.

https://flic.kr/p/2qeZMHe

As of this morning I'm here with it:

https://flic.kr/p/2qf1obo

I'm making life difficult for myself as I've tried to recreate the side bits so as to retain the original battery clips and springs. A bit difficult to see but the WORX battery is a couple of mm wider than the gap between the side bits.

https://flic.kr/p/2qeYbik

I might actually finish this one as time is of the essence

 

[ukracer]

Erm...I think you're forgetting what forum you're on! It's all about the journey as much as the destination!

Plus not all of us can afford new dewalt batteries and buy ferrex tools and batteries.

 

[Onoff]

Woke up this morning to the finished, lightweight, first test print of the WORX to old style 18V Makita battery. Printed on the X1C in our least favourite "bought as woodgrain" PLA.

First impressions pretty good:

https://flic.kr/p/2qfcgMo

We used black PETG as the separating layer atop the support:

https://flic.kr/p/2qfcgXo

Came off nice and clean. Note however the finger through the hole! A modelling error on my part:

https://flic.kr/p/2qfbXZo

So ref the bad bits! When modelling the recess for the tab I only worked on one side. When it came to do the other side I'd forgotten what I'd done and had to faff. Need to go back and look at the model. Easier said than done as on my ancient pc, modelling and rendering at this level often causes AutoCAD to have a hissy fit. Constant saving is the order of the day. "Unhandled access violation error" is the bane of my life doing these. Meant too I missed the big hole when rendering and rotating the model using the orbit function. (Need a new pc).

So where the original clips go in. They don't fit too bad for a first attempt. You can see where the leg has split mind. Might be to do with the minimal infill:

https://flic.kr/p/2qfbZCD

Deliberately broken off, you can see the rear wall the spring is retained against that's missing on the "finger hole" side:

https://flic.kr/p/2qfcpBX

The WORX battery held in. Still got to do the battery connector bit but that's fairly simply. I'll likely wrap the adapter around the rear of the battery:

From the front. Clearance for the battery is fine but I need to sort that wall retaining the spring clip and that might impact it:

Back to the drawing board for some tweaks when I can muster the enthusiasm!

 

[Onoff]

I must be a morning person...

Getting somewhere with the Ferrex to DeWalt adapter. Don't know where the enthusiasm came from this morning! I've beefed up where the screws will go. Undecided whether to use the originals or nuts and machine screws:

https://flic.kr/p/2qgra1A

https://flic.kr/p/2qgsp2G

Next a "mock battery" piece to go up inside the original, yellow tower section and keep the original DeWalt battery connector in place!

 

[Onoff]

@ukracer , I can't remember who sent me this Ferrex battery shell:

https://flic.kr/p/2qgsS5K

I'm now about to design the tower bit to support the original battery connector. In the actual battery one cell sits up inside.

https://flic.kr/p/2qgtPGy

Do you know if you have to connect to just B1+ and B- or B2+ and B2- to get 20V, or say both in parallel?

There's no innards with this battery shell so I'm guessing!

 

[ukracer]

@ukracer , I can't remember who sent me this Ferrex battery shell:

https://flic.kr/p/2qgsS5K

I'm now about to design the tower bit to support the original battery connector. In the actual battery one cell sits up inside.

https://flic.kr/p/2qgtPGy

Do you know if you have to connect to just B1+ and B- or B2+ and B2- to get 20V, or say both in parallel?

There's no innards with this battery shell so I'm guessing!

I don't have a clue about connections sadly. I also can't remember who sent you the shell.
I don't have a battery with me.
But can check later..

 

[ukracer]

It was @Migmac who sent you the ferrex case. He might know about connections.
it was @Turbo who sent the Parkside case.

 

[Migmac]

On that ferrex case it’s terminals B+ B- and T on the 20/40 battery it’s all 5 terminals.

 

[Onoff]

On that ferrex case it’s terminals B+ B- and T on the 20/40 battery it’s all 5 terminals.

Ta.

So is this:

https://flic.kr/p/2qgsS5K

The cover for this:

https://flic.kr/p/2qgv3iC

?

Thus my adapter pins need to fit into B2- on the left & B2+ on the right, as in they're offset with respect to the T pin?

 

[Migmac]

Ta.

So is this:

https://flic.kr/p/2qgsS5K

The cover for this:

https://flic.kr/p/2qgv3iC

?

Thus my adapter pins need to fit into B2- on the left & B2+ on the right, as in they're offset with respect to the T pin?

Yes, that is the same cover as the one for this battery pack

 

[Onoff]

I needed to figure the battery tower infill, to take up the space where one original cell fits . Not helped by the 5 yummy pints of Thistly Cross I've just had up the pub.

After a little snooze I took some measurements of the cell and a guesstimated height with the Vernier.

Got my lad to print a separate cylinder. I then slipped the original battery connector on and pushed it into the yellow tower. A dab of Super Glue on the end of the cylinder and I pushed everything together. I then took off the original, yellow top half and was left with this:

https://flic.kr/p/2qgzPy8

It's a fraction off laterally but that's correctable on the model. It's just where I pushed it together. I can now measure this and incorporate in the model.

https://flic.kr/p/2qgAMse

Next to engineer some channels in the cylinder to take the + & - wires.

 

[nickk]

Great dedication and ingenuity there Clive,well done go to the top of the class,jump the queue at your pub.

 

[Onoff]

Great dedication and ingenuity there Clive,well done go to the top of the class,jump the queue at your pub.

There is rarely a queue, believe me.

 

[Onoff]

A thought...

If I wanted to use this adapter with a 20/40V battery do I need to incorporate 4 battery connectors? Then do I wire the B1+ in parallel with B2+ and B1- in parallel with B2-.

I assume with a 40V tool it uses the batteries wired in series?

It seems silly, going to all this trouble to not be able to use it on 20/40V batteries.

Trouble it is too! As aforementioned, the modelling is stretching my pc beyond it's limits now and really tedious.

 

[ukracer]

A thought...

If I wanted to use this adapter with a 20/40V battery do I need to incorporate 4 battery connectors? Then do I wire the B1+ in parallel with B2+ and B1- in parallel with B2-.

I assume with a 40V tool it uses the batteries wired in series?

It seems silly, going to all this trouble to not be able to use it on 20/40V batteries.

Trouble it is too! As aforementioned, the modelling is stretching my pc beyond it's limits now and really tedious.

Yep. It would be no use to me if it only worked with 20volt batteries.

I only ever buy 20/40. As for how the connectors work I simply do not have a clue. I am sure it's documented on the net. I will try and find it.

 

[Onoff]

Another bit of the puzzle test printed. Integral rather than glued on battery connector support "tower". In the horrible wood effect pla. It works fine.

https://flic.kr/p/2qh8VAU

https://flic.kr/p/2qheKSK

https://flic.kr/p/2qhdzPi

https://flic.kr/p/2qhfhnZ

Next to figure the "blades" to connect to the battery.

 

[Migmac]

I can take the 20/40 battery pack out of its case and take photos of how it’s wired up if that will be of any help. I’ve no idea how it switches from 20 to 40