How do you build a battery pack for a supercharged drill

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Jeremy H

climber
Eagle, CO
Topic Author's Original Post - Aug 28, 2008 - 06:31pm PT
Hey everyone I have gotten a bunch of info on how to supercharge my drill from this site, but I still have some questions about the battery pack:

Which charger should I buy:

http://www.gruberpower.com/gruberpower/advertising/batteries/cutsheets/55-805000.asp

or

http://www.batteryspace.com/index.asp?PageAction=VIEWPROD&ProdID=2520

Also a couple more questoins:
How do you wire the battery pack.
Do I need quick connect on the batter pack
How do I attach the batteries to the charger
Is there a pos / neg on the drill, does it matter which wire I connect.

I have a bosch bulldog.

Thanks

Jeremy

Jeremy H

climber
Eagle, CO
Topic Author's Reply - Aug 28, 2008 - 06:57pm PT
Alright after a little more research it looks like I need to connect them in series, going pos to neg and neg to pos.

From the picture in this post is looks like there are four wires coming off of the batteries with a quick connect of some kind. Where do the four wires go?

http://www.supertopo.com/climbing/thread.html?topic_id=431576&tn=20

Jeremy H

climber
Eagle, CO
Topic Author's Reply - Aug 28, 2008 - 07:03pm PT
One more question,

Do I need a 24V charger or a 12V charger?
slobmonster

Trad climber
berkeley, ca
Aug 28, 2008 - 07:05pm PT
There absolutely a pos/neg within the battery's guts.

(When you open the thing up, note how the stock battery connects. This could help.)

I used quick connects on the batteries. They're easy to pull off... wire your charger with 2 quick-connects (aka paddle connectors?) and you just plug 'em in to charge.

Note in the photo below my wiring. Batteries are wired in series; this doubles the voltage. So for (my) 24V drill, two 12-V batteries in series does the trick.

slobmonster

Trad climber
berkeley, ca
Aug 28, 2008 - 07:06pm PT
Oh yeah. Buy a good crimping tool (ignore if you're solder competent) and some heat-shrink tubing.
Jaybro

Social climber
wuz real!
Aug 28, 2008 - 07:19pm PT
Yo Jer, have you climbed that .12 ow right there in Eagle Co? on private land, but visible from the interestate?
TGT

Social climber
So Cal
Aug 28, 2008 - 07:38pm PT
Steal one from a submarine

Juan Maderita

Trad climber
San Diego, CA
Aug 28, 2008 - 08:58pm PT
Jeremy wrote: "From the picture in this post is looks like there are four wires coming off of the batteries with a quick connect of some kind. Where do the four wires go?"
http://www.supertopo.com/climbing/thread.html?topic_id=431576&tn=20


The four wires with connectors in my photo are for charging each battery independently, with a 12v charger. That is my preferred method, because the internal resistance of each battery may not always be exactly equal. The wiring is slightly more complicated than Slobmonster's. I don't think there is anything "wrong" with using a 24v charger to charge the pair simultaneously. It's personal preference. I sometimes use the convenient 12v connectors as an outlet for 12v appliances, testing trailer lights, etc.

If you put your batteries end to end (rather than side by side) they will fit neatly in a fanny pack. Use aluminum flat bar stock as a stiffener/support and duct tape together in a bundle/ Wrap the works in closed cell foam.


"How do I attach the batteries to the charger"?

Use the alligator clips which come with the charger.


"Is there a pos / neg on the drill, does it matter which wire I connect."?

Yes, there is a (+) and (-) on the drill. Though, I couldn't tell you which is which. Since you have the model 11213 (non-reversing, it's easy enough to just guess. If the drill runs backwards (counterclockwise), then you will simply swap the wires. It won't hurt the Bulldog to get it backwards (can't guarantee the same for newer technology drills).
You can swap the wires at either one of the male or female plugs, or at the screw terminals inside the handle. If you have only one battery pack, then it makes no difference. You don't have to be compatible with another pack or a friend's system.





WBraun

climber
Aug 28, 2008 - 08:58pm PT
So slobmonster?

Shouldn't that plug coming from your battery pack be a female plug?

You have a male plug with the contacts exposed for some serious shorts.
Juan Maderita

Trad climber
San Diego, CA
Aug 28, 2008 - 09:05pm PT
Werner,
Good point. I have recently switched over to that configuration myself. The reason is that someone might grab a 24v Bosch and try to plug it into a 120VAC socket. Now that can't happen.
I made a removable protective sheath for the male plug from a 3-prong adaptor. I cut the male prongs off the end so there is nothing "hot" exposed.
WBraun

climber
Aug 28, 2008 - 09:15pm PT
Juan

Nuetrik Powercon connectors work really nice for this type of application.

http://www.neutrik.com/fl/en/audio/204_390365502/PowerCon%C2%AE_20_Amp_productlist.aspx
Jeremy H

climber
Eagle, CO
Topic Author's Reply - Aug 29, 2008 - 12:03am PT
This forum is amazing. It has been really great to get quick informed answers! I have finished converting the drill, I did go with the male connector on the end of the drill. I am going to order the batteries tonight and a charger as well. I think I am going to go with the more simple design connecting the batteries in series and charging them with the 24V charger. Do you think I can cut off the alligator clips on the charger and connect the wires to a male plug to make charging easier? Thanks again!

Jeremy

30 mimutes later:

I have ordered my gruber batteries, I actually got 8amp batteries because they don't make a 7amp right now, and the 8 was about the same size and weight. I am not sure which charger to get. The 24V charger that I linked to above is for 10amp and above, does this matter?
Juan Maderita

Trad climber
San Diego, CA
Aug 29, 2008 - 02:19am PT
Jeremy wrote:
"I think I am going to go with the more simple design connecting the batteries in series and charging them with the 24V charger"

Either setup has the batteries connected in series. My setup has the added ability to be charged with a 12v charger.

I forgot to mention that another advantage I have is recharging from a vehicle's cigarette lighter when I'm 20+ miles of dirt road away from a wall outlet. That's the third good reason to take the extra step of adding two short pairs of wire for 12v charging.

As I write, my batteries are charging up for Labor Day weekend :)

Let us know how your Bosch conversion works out for you.
-John
Juan Maderita

Trad climber
San Diego, CA
Sep 18, 2008 - 05:56am PT
I built two more battery packs and took digital photos this time around.

Aluminum bracket for securing two SLA batteries. 1/8" x 1" flat bar stock. A layer of duct tape is then wrapped over the outside.

Pre-wiring the connectors before installation.

Two 12v, 4.0Ah, SLA batteries, wired in series for 24v output at the male plug. There are two pairs of wires for charging with a 12v SLA smart charger. The gray adaptor (w/ male prongs cut off) is a protective cover for the male plug to prevent a short during transport.



The package is securely wrapped in duct tape to prevent connectors from pulling loose and shorted circuits.

Wrapped in protective closed cell foam. I hope the wife doesn't notice that her yoga mat is 2' shorter...

The completed SLA battery pack for a 24v Bosch rotohammer.
Buckle added in case the zipper blows. Hammer holster and gear loops added to the waist belt.

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