Rebuilding DS160 battery packs

Just curious if anyone has ever rebuilt an Ikelite DS160/161 battery pack?

Both of mine are now taking an age to recycle and charge and will stop completely soon.

Im not too keen on paying £200 each for new packs so wondering if anyone has managed to rebuilt their own just using cells bought elsewhere?

These are the NiMH version not the Li-Ions.

I can see the screws to get into them but wondered if anyone has successfully done this and if so, was it hard and what cells were needed?

Talk to Strikalite

https://www.strikalite.co.uk/prodcat_type/20/ALL/0/Specialist_Battery_Packs.html

they may be able to build you one for a reasonable price

11 hours ago, String said:

Just curious if anyone has ever rebuilt an Ikelite DS160/161 battery pack?

Both of mine are now taking an age to recycle and charge and will stop completely soon.

Im not too keen on paying £200 each for new packs so wondering if anyone has managed to rebuilt their own just using cells bought elsewhere?

These are the NiMH version not the Li-Ions.

I can see the screws to get into them but wondered if anyone has successfully done this and if so, was it hard and what cells were needed?

 

If you are thinking of doing this yourself you need to be aware of a few issues.  Generally these are AA cells or sub-C cells and they are wired up in series mostly, the bridges between cells are generally spot welded in place with a specialist spot welder designed for the task to minimise heat input into the cell.  You can buy solder tabbed batteries which allow you to solder the tabs together rather than solder the tab to the battery terminal.  Definitely do not attempt to solder directly to the battery. 

Be aware that there is a lot of energy contained within these cells and if not done properly they can overheat. Use all new cells of known good quality - do not cheap out on cells or buy from random suppliers on Ebay etc.  I found this video for re-building a NiCd pack - rebuilding a NiMH should basically be similar: 

I would strongly suggest you exercise caution unless you are experienced with electronic repairs and soldering - it would be easy to damage one of your new cells or if you short it even at the low voltage they can do spectacular damage.

Failing that there are a lot of services that do battery re-packing, just google battery re-packing services.

I tried and failed :-)  The newer NiMH cells are just a bit bigger in diameter making it an awkward squeeze. (And maybe I am less handy soldering then I would want). I fit one, thougt i finished and then it started smoking (sghort circuit).. luckily straight away so no other casualties then those cells and my pride.

I had them rebuild by Ken from Aquaphot in the UK.

I didnt realise Aquaphot would do them.  Might be worth an email.