A solderless battery mod

[Some Guy]

Made from this dirt cheap "pill shaped keychain"

DealExtreme: $2.61 Aluminium Alloy Pill Shaped Keychain

Uses one protected 18500 3.7v 1600 mAh batt.
No wires or solder. Basicly two springs and a plunger/button with atty connector.

Pic posting attempt. The pill thing before and after and a 510 in there for scale.

Somewhat exploded view of parts (next pic). I apologise for crappy cellphone pics.
Bottom row from left to right.
1: Battery (atty) connector with bottom shell part cut off so as to make contact with the positive button on the batt.
2: Positive end spring with a bit of foam around it to center it (could not find the right spring locally).
3: Negative end spring bent more conical to miss washer on next item.
4: On off button/plunger made from the cut off part where the keychain attaches to (don't waste anything!).Tapped with a #6-32 1/2" long bolt,washer and nut attached to stop it from falling out and adjustment.

Next pic is a feeble attempt at a close up of the button and batt/atty connector.

I did this with a cordless drill, a dremel and a tap ($4). So anyone can do it, it's almost free and it's shiny.
My first battery mod so cut me some slack.
More info if anyone cares.

 

[doots]

Very Nice Job

 

[Some Guy]

Thank you Doots
Love the avatar!

 

[DaMulta]

i like it, and how does the button fill?

 

[Some Guy]

i like it, and how does the button fill?

Don't understand your question DaMUlta..Maybe because I have had a few sorry.

 

[Stormynights]

That is very nice. I like it a lot.

 

[Some Guy]

Thank you Stormy.

Maybe Damulta's question was "how does the button feel?"?
I tried to keep the button pressure easy..I used the same spring at each end. The negative end spring is widend and the positve end spring is more compressed making the positive end a bit stronger.So it stays normally off.Only 1/8" travel in the button.

 

[Flip7990]

When are you going to start selling them??

 

[bearscreek]

When are you going to start selling them??

I'm in.

 

[Some Guy]

I was thinking people could make their own and save a $100 dollars or more.
I can take your money or help you make one lol. But seriously I don't have it down well enough to sell (yet).This is version 1.1 and I was just sharing.Thank you though.

 

[Nuck]

Looks simple, clean and easy and uses a great bat size. Very nice job.

 

[hittman]

I like it! It just goes to show almost anything can be turned into a pv.

 

[one_raven]

I like the clean, industrial look of it.
Nice work.

 

[nubee]

No cut of slack needed at all!!! This is brilliant!
Simply, clean and no solder which is a big plus in my book at least.

Very nicely done.

Question: You have to make sure the button/switch makes contact with the outter shell to complete the negative circuit connection yes?

 

[one_raven]

How is the button attached? I don't see the nut protruding.
Can we get a shot of the back-end with the button in view?

 

[warp1900]

Very nice looking mod, I like that you can use a 18500 battery in it.

Cisco made the much smaller version that only fits a 14250.

I am trying to figure out if there is a way to fit a switch in a better area since I am not a fan of the SD style switch, of course that would make it a wired mod.

 

[nubee]

How is the button attached? I don't see the nut protruding.
Can we get a shot of the back-end with the button in view?

I believe the washer and nut are inside preventing the button from falling out.

 

[one_raven]

In my experience, it is usually:

(outside)nut|body|switch(inside)

 

[nubee]

The button is not really a button/switch in the rat shack sense. It is just a plunger that pushes the plus side of the battery up and onto the atty. That's the really cool part to me is that there is no solder needed.

"4: On off button/plunger made from the cut off part where the keychain attaches to (don't waste anything!).Tapped with a #6-32 1/2" long bolt,washer and nut attached to stop it from falling out and adjustment."

 

[one_raven]

Nice!
Thanks