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Remove Spot weld

Discussion in 'Electronic Basics' started by Terry Pinnell, Feb 2, 2005.

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  1. I had a similar situation once. I did manage to get them apart; seem
    to recall 'tearing' or cutting. Obviously need to retain as much of
    each tag as possible when cutting. Then I was able to place solder on
    the tags. Position solder spots so that you can fold up afterwards.
    Also place solder on opposite side on one tag, so that when (large)
    solder tip applied it will melt solder on other side of tag, against
    which you've pressed the next battery's tag. If there really is
    insufficient tag left after cutting to enable 're-folding', solder on
    some heavy wire or tin strip.

    Easier to do than describe <g>.
  2. Lord Garth

    Lord Garth Guest

    Cut them apart with a cut-off wheel, Dremel for example. Our local
    hardware store has a spot welding setup for building custom battery
  3. Trudeau

    Trudeau Guest

    I have a rechargable drill that has some batteries that are bad. Id like to
    replace them. Inside the battery pack are 10 or so rechargable batteries.
    The problem is that they are connected together (in series) with a tang of
    metal that is spot welded to each battery connecting them together. I dont
    think I can un soder this, as its not really sodered. Its spot welded. I
    could cut the tang I suppose but dont know How I would connect this up
    again. And do it in such a way that will let me fit it back into the drill
    pack it comes from. (Obviously I want to replace some of the faulty
    Any advice.

  4. ghl

    ghl Guest

    I use a small drill bit (just a tad larger than the spot weld) and drill
    them out. you will have a larger part of your tab left. also I bought some
    batterys and they gave me some new tabs that will solder back on the
    just a thought.
  5. Trudeau

    Trudeau Guest

    Thanks all. For your answers. Glad to know that there are really no perfect
    answers. At least I know that. Certainly the drilling of the spot weld is
    the most creative. Not sure if that will work in my case as it may drill
    into the battery. Although I suppose if that particular battery is bad then
    It doesn't matter!

  6. Externet

    Externet Guest

    Fit a knife edge between the tab and the cell body, hammering the
    knife the spotweld gives up leaving a neat full lenght tab that can be
    soldered to the new cell. Scrape the new cell and tin it before
    soldering it to the old tab.
  7. Guest

    I used to recondition NiCad belts for a professional film rental
    company. I built a load tester that matched a typical camera. When the
    weakest cell would drop out the test rig would alarm and I'd mark the
    bad cell. In this way we'd test each belt and keep them near the rated
    I also recondition batteries for my 9.6 V Makita tools. I tend to cut
    the tabs as long as possible and resolder them together using a
    modified solder gun. It's just uses two bare copper 10 ga? solid wire
    filed to a flattened squared point with a ~ 1/4" seperation. I crimp
    the tabs together and use the gun to heat the joint. Cool sparks. Works
    a lot better than a regular gun. ( of course a spot welder would be the
    best solution). You also can as suggested above cut the tabs off with a
    knife or sharp chisel. This I have to do most often to deal with the
    thermal cut out or the end leads that form the contacts. I usually try
    to avoid this by scrounging good end batteries. I have found NiCads in
    recycling bins that were brand new but had cracked housings, broken
    contacts or had been run over.
    Be very careful not to short the battery out. This can be very
    exciting! I avoid this by repackaging the pack and connecting the two
    middle batteries through the open end as the last thing (The Makitas a
    stick battery 4X2 and the end is where it "turns the corner").
  8. Trudeau

    Trudeau Guest

    Thanks again for all your suggestions. Im going to try this weekend to see
    what are the best options for me.
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