BOOM!
Here we go!!!
Mark this day on your calendar! A year from now when the world looks much different I'll reflect back on how important today was and what it was the start of. Well, it officially started yesterday but I'm celebrating the sun rising (with my cofveve) on the start of a new world! 
Some know and are dancing, long awaited.
Popcorn ready! 
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Hey mare ze dotes! Morning! Welcome! Pull up a chair and get comfy.
I'm (whacky) Willy and (as late) pop in and out from time to time. Yeah, KTM took one for the team and started this thread, good man.
Pulled one of my ebay zzbmod's with a 75 board into rotation yesterday and it was dead... Wouldn't even light up when plugged in and escribe couldn't see it. I opened it up and this one was one with a parallel pack, the first one I made long time ago using three tenergy nano cells, checking the voltage at the board with a DVM I found just over 2 volts, not good. Figured the board died and was drawing the cells down, cut the battery wires, plugged the board back into escribe and it was fine. Threw a 18650 and sled into it for a quick fix and she's back up and running fine, never seen one act like that before.
What sled are you using in those ZBBMod enclosures?
Credit goes to a awsum or steamer for the tip on these sleds for these mods, sorry guys I don't remember which one of you gave me the tip but I know it was one of you. Yeah I'm loosing my mind, literally (or illiterately?
) but we all know that don't we? Aww heck, I just can't remember $**! anymore... Anywho, I bought a ten pack bag of them some time ago, don't remember if it was off Amazon, ebay or one of our China sites we talk about often here but likely one of them and surely the price was cheap or I wouldn't have bought them, I probably spent days searching to save half a buck... The name and part number on them is 18650-PC2 BLOSSM and a quick search found the maker and pics confirm this is the one --> 18650 Li-ion Battery Holder with PCB Pins - BLOSSOM POWE SUPPLY
Using a razor knife I had to trim back and round off the corners on one end of the holder so it fits formed into the lower end of the mod, it just squeezes in past the large 510 they used in these mods and the bottom of the enclosure, it's a very tight shoe horned fit but it sure won't move around once in there. On the inside of the enclosure, on the back half I put two layers of thin dense foam to hold the battery down in the sled. Scrounging my bench I found there is a thin black foam piece in the floor of a steam crave mizer box.
Nothing goes to waste around here, not much gets thrown out either. 
My wife is not allowed in my office, she would happily throw everything away in here if she could.
Out of all of this big house my office is the only place that is mine and mine alone, well other then the shop/garage and she wants no part of that mess either... And that's only because I'm the fixer of anything that breaks, cars, lawnmowers, toasters... and the rule is if I have to be the fixer than the shop is mine.
Well the credit rightly isn't mine, I'm just the messenger.
I noticed one thing after posting and having it apart for the pics, the atty isn't seating, screwing all the way down on the 510, I thinking maybe inside the center 510 pin might be hitting the battery sled but a little trim on the upper corner of the sled will likely give clearance, something to look at when you go to do one. Not that it really is an issue, the gap is slight and the mod is tight in the 510, had it in my pocket while doing all the trimming with the push mower and the atty never loosen during all that, just something I noticed. At some point I'll take one of those zbbmods lipo's apart and resolder it to another parallel pack, just didn't want to take the time yesterday and those 18650's give close to the same run time, little less but close enough.
Oh, one other thing, the wires soldered to the contacts on the sled, I snipped the tab that hangs down outside the backside of the tray, didn't want them making contact inside the mod. I pulled the contacts from the sled, first soldered the wires to the back side of the contact but when I went to push them back into the sled it wouldn't fit in the grove because of the wire in the way, so I resoldered them to the inside and feed the wire down through the center slot in the tray, I should have opened that slot up a little but force took over and I JAMMED it in Grrrr... LoL, you'll see what I'm talking about when you get them.
So anyway, I'm too lazy to read the pages I missed... Everyone doing OK? Did I miss anything juicy??
Mike, I replaced the contacts in the sled. I used two layers of brass shim, soldered together, for the positive contact. I replaced the bottom contact with a beryillium spring and used another piece of brass shim for the actual contact. That shim is connected with a piece of braided copper, coax shield, through the center of the spring and then a piece of 14 gauge silicon soldered to that to get to the board. JB weld holds the positive contact and the spring very nicely.
It took some filing to get the sled to fit into the enclosure and the sleds I used "wrap" around the battery to hold it. It holds so well I had to add a piece of ribbon on one end to get the battery out. I used magnets on the case so I can just swap batteries as needed.
It took some filing to get the sled to fit into the enclosure and the sleds I used "wrap" around the battery to hold it. It holds so well I had to add a piece of ribbon on one end to get the battery out. I used magnets on the case so I can just swap batteries as needed.
There ya go, now the neurons are firing, it was you that told me about using these sleds.
I just went to get the photos and Flickr is down for maintenance, moving to new hardware. I hope it goes better than WeaterUnderground.
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