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Zenith SupersPORT battery rebuild

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    Originally posted by GiGaBiTe View Post

    You need nickel strips like this:

    Another option is to get some stranded copper wire, like 18 gauge. Strip a long section of it, twist it tightly and then hammer it into a flat strip. An issue you may have is that the copper will be a lot thicker and make the battery assembly longer, which may not fit into the case properly.

    You'll also need some fine sandpaper to lightly sand the battery tabs so that they'll take solder. You can use any kind of rosin core solder, I prefer the 60/40 leaded stuff because it's a lot easier to work with.
    Awesome, it feels like a plan coming together... One part that I'm a little fuzzy on, how do you solder the ends of each battery together, since they'll be touching? Do you sort of fold the strip over after you solder it to each end? Or do you only solder the batteries that aren't end to end?

    don't really know without seeing where all three wires go.
    It's the white one in the pics I posted. It goes to this corroded cylindrical thing that is strapped to the batteries and then to the positive end. Here's a pic if you can't make it out I'll take another one when I get home.



      Most likely it is a thermal fuse to protect the battery.


        Ah! Here's a better picture for kicks.


          Yeah, pretty sure that's a thermal fuse, which is why it's bonded right up against the battery. If it's still good, you'll want to use it on the new pack, if not you'll need a replacement.


            Any idea why the thermal fuse is on its own separate wire instead of directly in line with the battery? There also appears to be a thermal fuse at the other end of the pack between the groups of cells.


              If it's something like a thermistor, it'll be in circuit with a transistor/mosfet to cut power to the battery, you can't slap a thermistor across the full current of the battery, it wouldn't work. The white wire should connect to one of those transistors/mosfets on the board that's all corroded.


                The C size nimh cells I was eyeing on amazon for this went on sale today, got 10 cells and the strips for $43.


                  Not bad. Hope they work out.


                    Dismantled the old battery pack in preparation for rebuilding. Took some extensive pictures. The circuit board almost looks burnt around the battery connector. Should I just make a replacement? See various attached pictures.
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                      Looks like the middle pin thing is this:


                        Tested the pepi c with a heat gun and multimeter and it seems to be functioning as indicated in that sheet I posted so I’m gonna say it’s still fine.


                          Looks like I missed a critical element in my earlier photos. This thyristor is presumably what reacts to that pepi c thermostat switch.



                            Ok the battery pack is all together (12.87V! Oh yeah!). I looked at reusing the connector/wiring but it is absolutely soaked in corrosion, wicked up the wire just like you said. So now I need to order another connector…any idea what this connector is called or where to buy one?


                              It looks like a Molex KK series connector, but yours looks to be bigger?


                              You'd need to measure the pin pitch and pin diameter to find a match. I guess if you have any 3 or 4 pin computer fans sitting around, you could see if the connector fits.


                                Ah yes. The pitch is about 3.5 mm, see photo.
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