Bosch cordless drill internal plug (connects with external battery)

thingiverse

This is a versatile plug compatible with multiple Bosch tools ranging from 7.2 to 14.4 volts. My Bosch PSR 14.4-volt VES-2 tool from 1996 was my test model. I do not have knowledge about the connectors on later introduced 18-volt tools. This plug replaces my worn-out NiCd battery using an external NiCd battery pack connected through its loader. The plug is also suitable for some budget-friendly 18-volt batteries produced in China, as long as their connectors are checked and compatible. I examined common 18-volt batteries on the market to confirm compatibility. Nowadays, this drill can be powered by alternative energy sources like external batteries or car battery chargers from third-party suppliers. To make use of this adapter, some DIY skills with soldering and tweaking will come in handy. This product only includes the plug; other essential components are: - Drill attachment options (pick your preference) Note: The initial design required hand-drilled holes, but updated files have since fixed that issue, along with minor cosmetic adjustments. Additional needed materials: - 4 self-locking nuts (M4x16, M4x40) - Scraps for the tension retainer and a mount plate if desired - Red/black LY10 or similar wire (1.5mm^2) for connectivity --- **Post-Manufacturing** Inspect your drill to begin assembly. The plug must be able to sit properly against it. Compare the socket on your drill with my attached files; ensure both sockets have a symmetrical shape with two parallel channels running along their center. This setup allows secure engagement and functionality between both parts. Modify the bottom component first since that is where two holes are needed, around 2mm in diameter. These guide wires through specific slots. Using the provided strip of metal sheet (usually from a binder clip), clean it by scraping off any dirt or old paint left on the metal strip. Shape it into an 'L' to match my pictures, creating contacts. Place them through small openings on your drill's bottom part and secure with some screws. Wire connections should then pass underneath for proper placement. Secure short wires using a screw at their ends if feasible, bend them into a circular shape after, cut excess wire, place the shorter ones between metal strips for easy wiring to top sections without the tension being loose at all points once everything gets fitted. Now attach middle plates (from left-right orientation view on both) before stacking onto lower plate secured via 16mm bolts using 14 x locking nuts. Mount (self-locking) nuts onto upper half now which goes over entire structure assembled previously. Assembly of the project isn't done yet as final adjustments must happen; it may be necessary depending upon thickness choice, otherwise wires wouldn't be clamped firmly by clamp located near middle area - preventing shorts because these should only occur with proper fit. Finally inspect every lead for proper continuity & function when using power source nearby checking that none shorts are occurring everywhere conductively speaking always prior adding load via attaching lamp before placing it onto the desired object being energized or just attach if safe practice has proven satisfactory thus completing setup effectively as well.