Trystan Casey
Converting a battery drill to electric involves a process of soldering wires to the battery pack contacts and potentially removing the battery clip. This method allows for the continued use of the drill as a corded tool, bypassing the need for battery replacement. The process requires specific tools, such as a soldering gun or butane torch, and knowledge of electrical engineering to ensure safe and effective conversion. It is important to note that the power requirements for tools can be surprisingly high, and the cost of a power supply may rival the cost of a new corded tool.
| Characteristics | Values |
|---|---|
| Cost of new batteries | Expensive |
| Cost of new unit | $20 |
| Cost of replacement batteries and charger | Not worth the money |
| Craftsman Drill/Driver cost | $5 |
| Wall wart cost | Free |
| Wall wart voltage | 12v |
| Wall wart amperage | 1.2A |
| Higher voltage | Higher rpm |
| Lower amperage | Less power |
| 1A | 1000 mA |
| Tools | Screwdriver, sandpaper, soldering equipment, butane torch, solder, flux wire cutter, wire stripper |
| Process | Open up the drill, figure out which leads on the drill and power supply are which, cut the end off the power supply, strip and tin the ends of the wire, sand, flux and tin the battery connector, solder the power supply wires to the battery clips, put it all back together |
| Cordless drill with dead battery | Convert to corded and continue to use in corded way |
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What You'll Learn
Identify the battery pack's voltage and amperage
To identify the voltage and amperage of a battery pack, you will need to use a multimeter. You can choose between analog and digital multimeters, each with its unique features, advantages, and disadvantages. Digital multimeters offer higher accuracy and are ideal for precise measurements.
Firstly, check the battery's voltage rating, which is usually printed on the battery or in the device's manual. The voltage rating is important as it will determine the multimeter's mode and settings. The multimeter's mode should be set to DC voltage, and the range should be set higher than the battery's voltage. For example, if the battery is 1.5V, set the range to at least 2V.
Next, connect the multimeter to the battery. Ensure the battery is disconnected from any circuit to prevent external circuitry from affecting the measurement. Connect the red probe to the multimeter's current input or the VΩmA port, and the black probe to the common (COM) input. Then, connect the probes to the battery terminals, with the red probe on the positive terminal and the black probe on the negative terminal.
Now, observe the reading on the multimeter. If the value is considerably low (e.g., less than 1V for a 9V battery), the battery may be faulty or dead and needs replacement. A healthy battery will deliver a current close to its rated capacity.
Additionally, you can perform load testing to assess the battery's capacity and health. Connect a load tester to the battery terminals and apply a load matching the battery's rated capacity. Measure the voltage drop over time to identify weak or failing cells and evaluate voltage stability under operational conditions.
It is important to note that Lithium-ion batteries have a limited number of charge cycles and can be damaged if discharged below a certain voltage. Always consult the manufacturer's specifications before performing any tests or modifications to ensure safety and prevent potential issues.
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Find a suitable replacement power source
The first step in converting a battery drill to electric is to find a suitable replacement power source. This can be done by checking the side of the drill for a description of the battery pack and then looking up what type of replacement battery would be suitable. For example, if the drill uses a 9.6v, 1400 mAh battery pack, a replacement power source with similar or higher voltage and lower amperage can be used.
It is important to note that the power requirements of cordless tools can be surprisingly high, even when using a replacement power source. A laptop power supply, for example, would not be sufficient to power a drill. The cost of building a converter to deliver the required power may even rival the cost of a new corded drill.
One option for a replacement power source is to use a "Wall Wart" transformer. These can often be found at garage sales or second-hand stores and can provide the necessary power to the drill. For example, a 12v, 1.2A Wall Wart can be used to power a drill that originally used a 9.6v battery, with the higher voltage resulting in a higher rpm.
Another option is to solder wire directly to the battery pack contacts, bypassing the old battery elements altogether. This method requires stripping and tinning the ends of the wire, as well as sanding, fluxing, and tinning the battery connector. This method creates a permanent connection, so it is important to be confident in the soldering process before proceeding.
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Open the drill and identify leads
To convert a battery drill to electric, you will need to open the drill and identify its leads. This is a crucial step as it will allow you to understand which leads on the drill and power supply correspond to each other.
First, locate the screws that hold the drill together. These are usually located on the sides or back of the drill. Once you have found the screws, use the appropriate screwdriver to remove them. If your drill has a sealed casing, be aware that opening it may void the warranty.
After removing the screws, carefully pry open the drill casing. You may need to use a flat-head screwdriver or a similar tool to gently separate the casing halves. Be careful not to damage any internal components or wires during this process.
With the drill open, you should see the internal components, including the motor, gears, and battery compartment. Identify the leads coming from the motor and any other relevant components. These leads are usually colour-coded or labelled, so take note of their colours or markings. You may also find it helpful to take a photo or make a sketch of the drill's interior to refer to later.
Once you have identified the leads, you may need to solder or connect them to your new power supply. Be sure to make a note of their positions or mark them clearly before proceeding.
By carefully opening the drill and identifying the leads, you can ensure that you are making the correct connections when converting your battery drill to electric power.
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Solder wires to battery clips
To convert a battery drill to electric, you will need to solder the power supply wires to the battery clips. Here is a detailed, step-by-step guide on how to do this:
Firstly, strip and tin the ends of the wire. Sand, flux, and tin the battery connector. If you prefer, you can remove the battery clip and solder wire to wire instead. It is recommended to use a soldering iron for this process. Ensure you have the correct type of solder for your soldering iron – in this case, you will need rosin core solder.
Before you begin soldering, it is important to prepare the battery. Take a file to the positive and negative ends of the battery and rough them up. Make sure the whole surface of the battery terminal is evenly rough, and don't worry if you mess up the covering a little bit. Secure the battery in a vice, clamp, or a small woodworking "jig".
Now, you can begin soldering. Ensure your soldering iron is clean and then tin the tip of it. Heat up the terminal of the battery with the iron and apply solder. The solder should pool on the terminal. If it doesn't, you need to roughen the terminal up more and try again. Both parts must be heated, so make sure the iron tip is in contact with both parts.
Strip both ends of each wire and then tin one end of each wire. Heat up the solder on the terminal with the iron and insert the tinned end of the wire into the solder pool. Red wire is positive, and black wire is negative/common/ground.
Finally, test your power supply with a multimeter. If it doesn't work, remove the soldering iron to let the joint cool down, brush the joint to clean it up with a wire pencil or a little flux, and then repeat the process.
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Test the power supply
Testing the power supply for your battery drill is a crucial step in ensuring its proper functioning and safety. Here are some detailed instructions to help you through the process:
Understanding the Basics
Before you begin, it's important to understand the fundamentals of power supplies and the requirements of your drill. Drills typically consume a lot of amps, so you'll need a power supply that can provide sufficient amperage. Check the voltage and amperage requirements of your drill, which should be listed on the labels or in the user manual.
Testing with a Multimeter
One of the most common tools for testing power supplies is a multimeter. Set your multimeter to the voltage setting and touch the probes to the corresponding terminals on the power supply. For instance, touch the black probe to the negative terminal and the red probe to the positive terminal. Compare the reading on the multimeter with the voltage listed on the power supply. If the reading is at or close to the listed voltage, the power supply is functioning correctly.
Load Testing
A more comprehensive way to test your power supply is by using a load tester or a dummy load. These devices simulate the actual load that your drill places on the power supply. Programmable DC loads allow you to simulate various scenarios, such as driving screws or drilling through metal. This type of testing helps ensure that your power supply can handle the demands of your drill and prevents potential damage from overload.
Testing with a Car Battery
If you're considering powering your drill using a car battery, as suggested in some DIY guides, you can perform a similar test. Connect your car battery to the drill using thick wires and chunky crocodile clips. Observe how the drill performs when drawing power from the car battery. This test will help you determine if the car battery can provide sufficient power to your drill.
Safety Considerations
Always exercise caution when working with electrical equipment. Ensure that your power supply is rated for the voltage and amperage requirements of your drill. Using a power supply that cannot deliver the required current may lead to shutdowns or damage to the drill. Additionally, be mindful of polarity when connecting the power supply to the drill to avoid any mishaps.
By following these steps and guidelines, you can effectively test the power supply for your converted battery drill, ensuring optimal performance and safety during operation.
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Frequently asked questions
Converting a battery drill to electric power can extend the life of the tool, and you can avoid the cost of buying new batteries.
You will need a replacement battery pack, a wall wart, a screwdriver, sandpaper, soldering equipment, a butane torch, solder, flux wire, and a wire cutter.
First, open the drill and identify the leads on the drill and power supply. Cut the end off the power supply and solder the wires to the battery clips. Test the power supply with a multi-meter and reassemble the drill.
Yes, one alternative is to remove the old battery elements from the battery pack and solder wire to the battery pack contacts instead, converting the drill to a corded tool.
