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Old 01-25-2014, 03:57 PM #1
nlrunkle
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How to make replacement battery packs for Angel's

So this is a how to on how I make my replacement packs for ones that have gone bad in the older Angels. What is shown is the making of a 6v pack but the steps are just the same for a 4.8v pack for the 03/04, A4, A4 Fly, G7 and G7 Fly markers. Just leave out one battery.

First I start off with 5 Tenergy 2/3A batteries. I use the ones with the tabs. And I use the wire harness from a donated bad battery pack.





First thing I do with the first battery is cut the cover off of the positive tab.



Next thing I do is grab the second battery and pull the negative tab off completely.



If there is anything left of the tab, i take a file to it to make sure that I can get the batteries as close as possible so that they 1.) they fit in the tube and 2.) are nice and tight when I go to shrink wrap them.





The next thing I do is to cut a small section of the cover off of the battery.



End result should look like this.



I took a piece of 80/20 that was laying around and milled it out to fit the size of the batteries to act as a holder while I am assembling them. Put the backstop on there so that I can make sure they are tight against one another when assembling.



Add a little flux and some solder.

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Old 01-25-2014, 04:15 PM #2
nlrunkle
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Bend the positive tab down onto the outside of the battery that you cut you the cover.



What it should look like when your done.



And just repeat 3 more times.



I don't worry about how the solder looks or if it's to big and globby. I care more about that it holds and doesn't come apart. I'll go back over the spots that I think might not fit in the tube and file them down a little.



Place a piece of tape across the exposed contacts.



Grab a donor harness. Notice this harness also needs the wire solder back onto the switch as well. Most harness I run across always need some other work done to them. Or maybe the switch is bad but everything else is salvageable.



I even reuse the cardboard covers that came on the stock battery. Positive wire already solder on to the top of the last battery.



Length of heat shrink cut and the battery placed inside.



All shrinked down nice and tight





Fixing the switch...



And testing....




Well there it is, that's how I make my battery packs for the Angel markers. I hope this helps a few people that are looking for ways to keep their Angel up and running.
If you have any questions, concerns or need a little help, just shoot me a PM.
Enjoy
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Old 01-25-2014, 04:56 PM #3
EastCoastAngel
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Seriously kickass of you Nate....thumbs up bro
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Old 01-25-2014, 04:58 PM #4
trancer23
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Thank you for doing is. I vote sticky

What size heat shrink?
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Old 01-25-2014, 05:11 PM #5
dr.strangelove
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Very nice tutorial. Might make a good addition to the Ultimate Sticky, just sayin'.

A note to anyone who isn't very familiar with battery soldering: work quickly. Try not to touch the battery with the iron for more than about 3 seconds at a time to avoid damaging the cell. If you don't get it the first time, let it cool down before trying again, don't just keep continuously applying heat or you're going to be very disappointed when you try to power it up.

Also, for anyone attempting a battery build from scratch, you can find a complete parts list with part numbers, pics, and links in the following thread: https://www.pbnation.com/showthread.php?t=4072911

I would also recommend testing the assembled battery before wrapping it in shrink tubing, because Murphy's Law demands it

Last edited by dr.strangelove : 02-08-2014 at 06:43 AM.
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Old 01-25-2014, 05:32 PM #6
nlrunkle
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The shrink wrap I used here is 1 1/2". Not sure the proper name for this type I'm using. I buy it from my local hobby store. Last round of packs I made they had a different size that I purchased and was using. I ran out and they didn't have any yet so I ordered some online and it was definitely not right. Believe it was a Polyolefin and when it shrank down the thickness of the sleeve itself was too big. It was in no way fitting in the tube.
Definitely have to pay attention to what heat shrink your buying if you do it yourself. Course heat shrink is inexpensive and the hard part is done making the pack. Just cut it out and try a different type and or size of heat shrink.
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Old 01-25-2014, 05:55 PM #7
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Thank you for adding this for the Angel Community...
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Old 01-25-2014, 06:26 PM #8
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Give a man a fish and he eats for a day, teach a man to fish and eats for a lifetime......or some crap like that.

Great job Nate!
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Old 01-25-2014, 06:42 PM #9
dr.strangelove
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Polyolefin shrink tubing normally has a max 2:1 shrink ratio (they sell 3:1 varieties as well), so you have to size it accordingly for your application. 1.5" polyolefin at 2:1 will only shrink to .75", obviously. 1" or 1.25" would be a good choice for the battery. Nothing wrong with the material itself, just something to be aware of.
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Old 01-25-2014, 08:18 PM #10
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Just thinking out loud, but is soldering the tabs even necessary? Shouldn't the pressure from the heat shrink be enough?
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Old 01-25-2014, 08:25 PM #11
dr.strangelove
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Soldering is preferable, the connection is much, much more secure. Technically you can get by without soldering if the cells are held firmly enough together. If you want to do it that way you would be better off using tabless cells.
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Old 01-25-2014, 08:40 PM #12
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I was thinking the tab with the cut into the battery like Nate showed, combined with the pressure of the heat shrink, would make a darn good connection
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"Even now in Heaven there are Angels carrying savage weapons."
"Did you ever notice how in the Bible, when ever God needed to punish someone, or make an example, or whenever God needed a killing, he sent an angel?"
BALLERS INC DESTROYED MY ANGEL

35 angels and counting......
Blue Black Impact Angel LCD, Doodoo Brown Dark Angel LCD, Dark IR3 & Ripper angel
94 Tippmann Pro-lite (old reliable)
Old Feedback - New Feedback
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Old 01-25-2014, 08:58 PM #13
dr.strangelove
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Nothing beats that mechanical connection you get with soldering, but with a purely pressure connection you want max surface contact and as little possibility of slippage as possible. Tabless cells are flatter so they will mate a little better on pressure alone, and there's less chance of losing contact if a cell rotates or vibrates out of position.
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Old 01-25-2014, 08:59 PM #14
trancer23
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Makes sense
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"Did you ever notice how in the Bible, when ever God needed to punish someone, or make an example, or whenever God needed a killing, he sent an angel?"
BALLERS INC DESTROYED MY ANGEL

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Blue Black Impact Angel LCD, Doodoo Brown Dark Angel LCD, Dark IR3 & Ripper angel
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Old 01-25-2014, 09:27 PM #15
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Thanks so much nate, very helpful!
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Old 01-26-2014, 11:43 AM #16
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Quote:
Originally Posted by kerry88mcclure View Post
Thank you for adding this for the Angel Community...
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Old 01-06-2015, 07:58 PM #17
nlrunkle
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Just made this last month for our resident LED whore
So yes you can make them for the LED as well. It was fun tracking down the NiCad batteries though.

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Old 01-06-2015, 11:40 PM #18
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you dont necessarily need a donor harness if you use copper tape.
http://www.uline.com/Product/Detail/S-19395/3M-Single-Coated-Tapes/3M-3313-Copper-Foil-Tape-1-4-x-18-yards?pricode=WY478&gadtype=pla&id=S-19395&gclid=CK2x_MyVgcMCFQhk7AodW2MAUw&gclsrc=aw.d s

you can solder wire directly to the copper tape
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Old 11-05-2019, 03:00 PM #19
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Where does the battery go, I have a very old Angel, that my daughter wants to use this week end. Need to make this fast, but did not want to go unscrewing to gun, untill I knew where they went.
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Old 11-05-2019, 04:26 PM #20
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Holding the gun as if you were shooting it, the battery is housed in the bottom left hand tube. On the LCD and IR3 you will remove the battery by unscrewing the end cap at the front of the gun and extracting the battery through the front. On the Speed and newer Angels you will remove the battery by removing the back plate and extracting the battery through the rear of the gun. You can find a cutaway diagram for your exact model in the corresponding manual, which you can find here.
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Old 11-06-2019, 04:27 PM #21
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This should be stickied
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