Written on July 19, 2010 at 6:21 pm by Power Tool Team

Rotary Tool Cordless

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Rotary Tool Cordless
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Tip for rebulid your power tools battery

Cordless power tools are a great convenience for both the professional and the do-it-yourself homeowner. Unfortunately, the rechargeable battery packs that power these tools usually fail within 18 to 24 months. What many tool owners do not know is that within these battery packs is a simple arrangement of rechargeable size C batteries, which they can rebuild themselves.

Open the battery pack. This is very simply done if the pack has screws that hold the case together. If the pack is a solid, one-piece molded unit, you will need to cut it open. Step 2 Attach a chisel tip to the soldering iron, and heat it up. Use the tip to cut an outline along the top of the base of the battery pack. Pull off the top and set it aside. Inside will be a group of C-size rechargeable batteries in a generic cardboard casing. Read the text on them, which will indicate whether the cells are Nickel-Cadmium (Ni-Cad) or Nickel Metal-Hydride (Ni-Mh). Step 3 Make sure that you purchase the same type of rechargeable battery cells unless you are sure that your charger and tool will operate with the other type. If so, use Ni-Mh batteries -- they are superior to Ni-Cad cells in that they do not develop a "memory" when charged to less than full capacity. Step 4 Take notes regarding the way the batteries are connected and arranged so that you can put the new cells in the same way. Heat up the connector to each battery in the pack and remove it. Step 5 Use a rotary tool with a wire brush attachment to clean off any oxidation on the contacts and connecting wires left in the pack. Refer to your notes and install the new batteries the same way as the previous arrangement. Solder the new connections securely. Step 6 Put the top of the battery case back on and fasten the screws, or for the molded pack that has been cut open, use a liberal amount of an epoxy adhesive to glue the pieces back together. Be sure to let the pack charge fully (overnight) before using it for the first time.

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Without having a multimeter, how could I find the total amperage on 8 AA sized NiCD rechargeable batteries?

These 8 AA batteries make up the power pack for a 9.6V cordless rotary tool which are barely taking a charge anymore. All safety issues aside, I'd like to figure out the total amperage so that I can modify the tool to run from an AC to DC power supply. I realize that this would be easier to figure out if I had a multimeter to measure the current that the motor is pulling from the batteries in the power pack (I'm guessing that's how it'd be done). Could I just guess the amount by adding the general amperage on a normal AA Nicd battery that has it's mAh (Milliamp Hour) listed?
Yes the tool is at least a year old, though most likely two. So with that assumption if I had a power supply with an output of 9 volts would 888mA be enough?

Since each battery is 1.2 volts, and the output was 9.6 volts, they were wired in series so the amperage for the whole power pack is the same as the amperage for a single battery. If this rotary tool is a few years old the Nicd AA batteries put out around 1000 mAh. (They are up to 2700 today!)

Any 10 volt adapter that puts out more than 1 amp should work.

And yes, if you find a 9.6 volt power pack that uses AA size batteries and has the specs listed you could go with that number. Good idea, actually! But keep in mind the newer one will put out more because of advances in battery design.

(I replaced the old "D" sized nicad batteries in my bicycle light with new "C" size and got twice the power at half the weight)

Dremel 8000-03 10.8-Volt Cordless Rotary Tool