Rebuildable battery packs?


Old 08-02-14, 07:52 AM
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Rebuildable battery packs?

Greetings from Oregon, the shower me state,
Recently I read an article in Handyman about rebuilding battery packs for tools as an alternative to retail packs that are so expensive. With this in mind I have an old B & D charger, two batteries and a couple of woodworking tools. I'm wondering if anyone knows if these batteries can be rebuilt. What I have are a pair of Black and Decker 98003 9.6V batteries.



Thanks and a lift of the lynch lid for any help on this.
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Old 08-02-14, 09:39 AM
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I haven't see you around in a while.

Any power tool battery pack can be rebuilt depending on how much energy you want to put into the job.

If the pack is held together by screws - the job is fairly easy.
If it's thermally welded shut/glued then you will have to cut the pack open. If not done carefully it won't fit in charger and tool correctly.

That looks like the 98003 battery pack that was part of their appliance interchange program. That would be a tough battery for you to rebuild. It would take eight cells of about $5 each.

I left you a link below that has it at fair price for a replacement pack.
Black & Decker 98003 Cordless 9.6V Tool Battery
Old 08-04-14, 11:03 AM
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Hi PJmax,
Been busy working on my Jeep and other such. Assuming that the cells are roughly the same size as C cells I don't know how they'd fit 8 of em in there.
Old 08-04-14, 12:46 PM
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There are more cell sizes than the common AAA, AA, C and D. There are 1/2 sub C, 4/5 sub C, 1/2D, F and many, many more. Generally you have to cut the pack open and see what's in side measuring the cells for diameter and overall length. You'll also have to decide if you want replacement cells with tabs on the end or not.
Old 08-04-14, 01:20 PM
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There are plenty of places that will rebuild them for you. I see one on Ebay that apparently only charges $36 for B&D 9.6v packs. A couple of others (that look a bit more professional) charge about $50.
Old 08-04-14, 01:37 PM
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I also read that same article, and from personal experience, its not as easy as they make it sound. I had a very hard time soldering the tabs to each battery. I think a spot welder would work better. I just need to find a transformer to make one.
Old 08-05-14, 11:51 AM
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Thanks guys for all of the responses, I may go with a third party rebuilder after some Jeep projects reach fruition.

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