From: Woody Smith (woodysmith_at_comcast.net)
Date: Sun May 15 2005 - 08:21:20 PDT
When I rebuilt my 2x00 battery pack with 2300 mAh cells it also
didn't fit.
I used fine 320 grit sandpaper to gradually remove excess plastic
until it fit. If you have access to a woodworker supply store choose
one labeled 'free cut' or 'no-fill' (these papers are designed for
sanding nitrocellulose lacquer). Grey or blue, not black, brown or
red. What you want is a sandpaper with a dry lubricant (Zinc
Stearate). This leaves a fine grey residue on the pack that will
reveal the high spots when inserted and removed by wiping off this
powder.
With this method I got a battery pack that fit smoothly.
Woody
On May 15, 2005, at 7:07 AM, Ola wrote:
>
>>
>>
>
> In the end I got around 48 hours of continuous use on the first
> charge before the batteries ran out. Pretty amazing! And IIRC NiMh
> cells increase slightly in capacity during the first few charge/
> discharge cycles...
>
> I did consider stripping the plastic off the cells and even made a
> small cut in one of the cells but then I suddenly realised that
> this would effectively short circuit the pack which would have
> disastrous consequences!
>
> [+] on cell 1 -> [-] on cell two, shell of cell 2 -> shell of cell
> 1 = the same thing as connecting [+] to [-] on cell 1
>
> I had cleaned out the glue and plastic residue from the old packs
> but they still didn't quite fit - as Frank pointed out the modern
> high capacity cells are ever so slightly wider than the original
> Newton ones. I suppose a Dremel is the only solution here.
>
> Ola
>
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