Electronics, Lighting, & Gadgets - NiCad Tab Repair

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brucewiley

11-14-08, 06:59 PM

The 12V NiCad pack for my old Cygolite HID headlight had a shorted cell in it so I took the thing apart (yeah, had to cut it apart). Zapped the bad cell and brought it back just fine for now but a tab fell off of the output positive cell terminal in the process. I assume I just need a good fairly high wattage soldering iron/gun to quickly solder a wire or tab back on to it. Any hints or suggestions? I just have a small iron right now but am looking for something more substantial.

While I have your attention and since I'm too lazy to search/read old postings, what is a decent and fairly inexpensive auto/smart charger for this 12V NiCad pack? The one that comes with it is your basic sucky wall-wart. I would like to be able to keep it topped off for occasional use.

Bruce

brokenknee

11-16-08, 05:45 PM

here is a good link on how to solder batteries. http://www.batterieswholesale.com/battery_tips/assembling.htm

you should have at least a 40 watt soldering iron. i just started making battery packs for some of my battery operated power tools, i have made six so far with no problems. do not hold the iron to long on the battery (no more than 3 seconds) or you will ruin the battery.

can't help you with the charger.

brucewiley

11-16-08, 06:48 PM

Thanks broke

After some consideration I think I would prefer at least a 100 watt gun to quickly solder a connection on, leaning toward 150 watts. Alas my last Soldering gun died a couple of years ago so I need to find one, stuck with a 25 watt iron right now.

I did find a method for spot welding tabs back on to batteries (as they were originally) that sounds interesting, I may give that a try. Take the soldering gun and remove the tip. Fashion two pieces of solid copper wire (I would assume 10-12 ga) making one end on each sharp. Fit these into the gun and use the assembly to spot weld the tab back on with about a 3 second on time.

I'll try that just 'cause it sounds cool.

Bruce

brokenknee

11-16-08, 07:49 PM

i did see that when i was researching making battery packs. i have not tried it, if you try it let me know how it goes.