The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics)

Parker · 26th February 2008, 12:20

I got the general plans for a DIY Capacitive Discharge Spot Welder off the internet and decided to give it a go. It actually works pretty well for building battery packs for various applications- including for the Meg.

Here's a list of the stuff that I used along with the approx cost for each item-

12-24v automotive stereo capacitor (5 farad)- $65
SCR (thyristor) off eBay- $28
Foot switch (momentary) off eBay- $10
Battery charger from old AUL canister light that I just couldn't throw away
12v / 14 amp power supply for faster recovery between welds (optional) $40
Battery holder and battery (C cell) for activating SCR gate $ 2
Electrodes made from 1/4" copper ground wire $2
Wire, connectors, cable clamps, fasteners, etc... $15
Stanley tool box from Wal-Mart $8
Battery pack components vary in price and are listed in a number of Rebreather World threads

It was actually a pretty fun project and didn't take all that long to complete.

Cheers!

Parker

netmage · 26th February 2008, 13:10

Nice work Parker....

Now put together step by step photo/instructions so us laypeople can build one..

Curious how many hours life you'll get off them compared to the 2xC from BatterySpace at half-third the cost.

-Tim

edit: Looks like the plans can be aquired here... ~$5 on ebay...
http://diy-battery-tab-welder.net/

Skipbreather · 26th February 2008, 13:47

And a link to the site where you found plans that actually work would be nice, too! Tools are good. Homebuilt tools are even better. Just might have to start rummaging in some really old junque boxes. I think I've got a capacitor about the size of a 2 lb coffee can somewhere.....

Parker · 26th February 2008, 20:03

Sorry I left out the links to the website that I got the idea from, I meant to add them at the end... These are free- no $5 to eBay!

Tab Welder
http://ledhacks.com/power/battery_tab_welder.htm

Tab Welder II
http://ledhacks.com/power/tab_welder%20ii.htm

Will let you know how the Lithium AA's perform.

Parker

Gilles · 26th February 2008, 22:50

Impressive. As I am likely to utilize these resources you have so graciously put here on Rebreather World, I will blob you, and encourage others to do likewise.

Thanks

(from a multi-battery hot solderer, with failed batteries during dives).

**Steve** · 27th February 2008, 06:07

Fvck me. I thought I had gone over the top when I used a 1 f cap when I built mine. Nice idea on the toolbox. I'll steal that idea if you dont mind

Parker · 27th February 2008, 10:06

It's a car stereo cap that had all the bells and whistles, including flashing neon lights, prior to me stripping it down to just the caps and aluminum case. I kinda doubt that it's a true 5 farad cap but the pretty box it came in had 5 farad on there so... take it for what it's worth!

Parker

Outlaw · 27th February 2008, 11:36

well done Parker,

any idea where one can be supplied all the hardware?

here is some green for this. i think all meg users should green you today...

Spyros

Parker · 27th February 2008, 20:31

Capacitive Discharge Spot Welder
12-24v automotive stereo capacitor (5 farad)- <here>
SCR (thyristor)- <here>
Linemaster foot switch (momentary)- <perform ebay search>
12v / 14 amp power supply- <here>
Battery holder and battery (C cell) for activating SCR gate- <any electronics supply store>
Electrodes made from 1/4" copper ground wire- <most any hardware store>
**Note: Electrode wire should be at least 10 AWG, 8 AWG would be better.
Wire, connectors, cable clamps, fasteners, etc...- <most any hardware store>
Stanley tool box- <got mine from Wal-Mart>

Battery Packs
Molex connectors- <here> & <here>
Molex crimp tool- <here>
3.6v Lithium batteries w/tabs- <here>
**Note: Welding tabs to the + end of the 3.6v Lithium cells is a bit tricky, as the welder doesn't perform well with aluminum.
These batteries can be ordered with the tabs installed for $0.25.
1.5v Lithium batteries- <here>

<here>
1.5v Alkaline batteries- <almost anywhere>
3" shrink wrap- <here>
24 AWG wire- <most electronic supply stores>
Nickel strip tab material (.125w x .003t or .125w x .005t)- <here>

It's a good idea to practice on old or cheap batteries before sticking the electrodes to the expensive Lithium cells.
Electrode contact and pressure is very important for obtaining quality welds.

Hope this helps!

Parker

Outlaw · 29th February 2008, 00:59

Quote: (Originally Posted by Parker)

Capacitive Discharge Spot Welder
12-24v automotive stereo capacitor (5 farad)- <here>
SCR (thyristor)- <here>
Linemaster foot switch (momentary)- <perform ebay search>
12v / 14 amp power supply- <here>
Battery holder and battery (C cell) for activating SCR gate- <any electronics supply store>
Electrodes made from 1/4" copper ground wire- <most any hardware store>
Wire, connectors, cable clamps, fasteners, etc...- <most any hardware store>
Stanley tool box- <got mine from Wal-Mart>

Battery Packs
Molex connectors- <here> & <here>
Molex crimp tool- <here>
3.6v Lithium batteries- <here>
1.5v Lithium batteries- <here>
1.5v Alkaline batteries- <almost anywhere>
3" shrink wrap- <here>
24 AWG wire- <most electronic supply stores>
Nickel strip tab material (.125w x .003t or .125w x .005t)- <here>

It's a good idea to practice on old or cheap batteries before sticking the electrodes to the expensive Lithium cells. Electrode contact and pressure is very important for obtaining quality welds.

Hope this helps!

Parker

Hey Parker,

i tried to green you again, but "have to spread the reputation before doing it AGAIN..."

thanks.

26th February 2008, 13:10	#2 (permalink)
netmage Tim Owens Current Rebreather/s: Megalodon Other Rebreather/s: Join Date: Dec 2005 Location: Coconut Creek, FL Posts: 520	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) Nice work Parker.... Now put together step by step photo/instructions so us laypeople can build one.. Curious how many hours life you'll get off them compared to the 2xC from BatterySpace at half-third the cost. -Tim edit: Looks like the plans can be aquired here... ~$5 on ebay... http://diy-battery-tab-welder.net/ Last edited by netmage : 26th February 2008 at 13:54.
(Offline)

26th February 2008, 13:47	#3 (permalink)
Skipbreather Reads the fine print Current Rebreather/s: Megalodon Home Build Other Rebreather/s: Not Bought Yet MK 15.X Home Build Join Date: Mar 2005 Location: Chicago, Illinois, USA Posts: 557	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) And a link to the site where you found plans that actually work would be nice, too! Tools are good. Homebuilt tools are even better. Just might have to start rummaging in some really old junque boxes. I think I've got a capacitor about the size of a 2 lb coffee can somewhere..... __________________ "Entropy RULES! Enjoy the interim."
(Offline)

26th February 2008, 20:03	#4 (permalink)
Parker what bubbles? Current Rebreather/s: Megalodon Dolphin Home Build Other Rebreather/s: Dolphin Home Build Join Date: Jun 2007 Location: USA Posts: 60	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) Sorry I left out the links to the website that I got the idea from, I meant to add them at the end... These are free- no $5 to eBay! Tab Welder http://ledhacks.com/power/battery_tab_welder.htm Tab Welder II http://ledhacks.com/power/tab_welder%20ii.htm Will let you know how the Lithium AA's perform. Parker
(Offline)

26th February 2008, 22:50	#5 (permalink)
Gilles Worship the feminine Current Rebreather/s: Megalodon Other Rebreather/s: Join Date: Sep 2005 Location: Den Haag (Netherlands) Posts: 762	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) Impressive. As I am likely to utilize these resources you have so graciously put here on Rebreather World, I will blob you, and encourage others to do likewise. Thanks (from a multi-battery hot solderer, with failed batteries during dives). __________________ Gilles http://www.dirrebreather.com
(Offline)

27th February 2008, 06:07	#6 (permalink)
Steve Ladies bring a plate Current Rebreather/s: Megalodon Home Build Other Rebreather/s: Not Bought Yet Inspiration Classic Sport Kiss Classic Kiss MK 15.X Home Build Join Date: Feb 2005 Location: Perth - Australia Posts: 1,117	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) Fvck me. I thought I had gone over the top when I used a 1 f cap when I built mine. Nice idea on the toolbox. I'll steal that idea if you dont mind __________________ WARNING: I contain occasional coarse language, extreme sexual references, nudity, and adult themes, which may offend some people - Usually churchy types.
(Offline)

27th February 2008, 10:06	#7 (permalink)
Parker what bubbles? Current Rebreather/s: Megalodon Dolphin Home Build Other Rebreather/s: Dolphin Home Build Join Date: Jun 2007 Location: USA Posts: 60	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) It's a car stereo cap that had all the bells and whistles, including flashing neon lights, prior to me stripping it down to just the caps and aluminum case. I kinda doubt that it's a true 5 farad cap but the pretty box it came in had 5 farad on there so... take it for what it's worth! Parker Last edited by Parker : 28th February 2008 at 02:17.
(Offline)

27th February 2008, 11:36	#8 (permalink)
Outlaw In search of Law breaking Current Rebreather/s: Megalodon Other Rebreather/s: Join Date: Aug 2006 Location: Cyprus, Nicosia Posts: 634	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) well done Parker, any idea where one can be supplied all the hardware? here is some green for this. i think all meg users should green you today... Spyros __________________ CMAS - IANTD - TDI Kamikazi Instrustor Trainer DIRRebreather Team Member ---------------------------- "Once an Outlaw, always an Outlaw"
(Online)

27th February 2008, 20:31	#9 (permalink)
Parker what bubbles? Current Rebreather/s: Megalodon Dolphin Home Build Other Rebreather/s: Dolphin Home Build Join Date: Jun 2007 Location: USA Posts: 60	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) Capacitive Discharge Spot Welder 12-24v automotive stereo capacitor (5 farad)- <here> SCR (thyristor)- <here> Linemaster foot switch (momentary)- <perform ebay search> 12v / 14 amp power supply- <here> Battery holder and battery (C cell) for activating SCR gate- <any electronics supply store> Electrodes made from 1/4" copper ground wire- <most any hardware store> Note: Electrode wire should be at least 10 AWG, 8 AWG would be better. Wire, connectors, cable clamps, fasteners, etc...- <most any hardware store> Stanley tool box- <got mine from Wal-Mart> Battery Packs Molex connectors- <here> & <here> Molex crimp tool- <here> 3.6v Lithium batteries w/tabs- <here> Note: Welding tabs to the + end of the 3.6v Lithium cells is a bit tricky, as the welder doesn't perform well with aluminum. These batteries can be ordered with the tabs installed for $0.25. 1.5v Lithium batteries- <here> 1.5v Alkaline batteries- <almost anywhere> 3" shrink wrap- <here> 24 AWG wire- <most electronic supply stores> Nickel strip tab material (.125w x .003t or .125w x .005t)- <here> It's a good idea to practice on old or cheap batteries before sticking the electrodes to the expensive Lithium cells. Electrode contact and pressure is very important for obtaining quality welds. Hope this helps! Parker Last edited by Parker : 2nd March 2008 at 06:43.
(Offline)

29th February 2008, 00:59	#10 (permalink)
Outlaw In search of Law breaking Current Rebreather/s: Megalodon Other Rebreather/s: Join Date: Aug 2006 Location: Cyprus, Nicosia Posts: 634	Re: The Jr. Professor Mr. Meg Battery Pack Builder Kit (w/pics) Quote: (Originally Posted by Parker) Capacitive Discharge Spot Welder 12-24v automotive stereo capacitor (5 farad)- <here> SCR (thyristor)- <here> Linemaster foot switch (momentary)- <perform ebay search> 12v / 14 amp power supply- <here> Battery holder and battery (C cell) for activating SCR gate- <any electronics supply store> Electrodes made from 1/4" copper ground wire- <most any hardware store> Wire, connectors, cable clamps, fasteners, etc...- <most any hardware store> Stanley tool box- <got mine from Wal-Mart> Battery Packs Molex connectors- <here> & <here> Molex crimp tool- <here> 3.6v Lithium batteries- <here> 1.5v Lithium batteries- <here> 1.5v Alkaline batteries- <almost anywhere> 3" shrink wrap- <here> 24 AWG wire- <most electronic supply stores> Nickel strip tab material (.125w x .003t or .125w x .005t)- <here> It's a good idea to practice on old or cheap batteries before sticking the electrodes to the expensive Lithium cells. Electrode contact and pressure is very important for obtaining quality welds. Hope this helps! Parker Hey Parker, i tried to green you again, but "have to spread the reputation before doing it AGAIN..." thanks. __________________ CMAS - IANTD - TDI Kamikazi Instrustor Trainer DIRRebreather Team Member ---------------------------- "Once an Outlaw, always an Outlaw"
(Online)

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