dewalt 18v to ryobi

thingiverse

So I was given some old DeWalt 18v tools with some dead batteries, and I couldn't find any 3D prints of a DeWalt 18v battery adapter. Since I couldn't find one, I decided to create this adapter myself. It could be refined by duplicating the real DeWalt battery bottom and just adding the Ryobi battery connectors, but I'm not skilled enough to do that. To use this adapter: I took apart the battery, removed the old cells, and cut open the bottom of the DeWalt battery near the back so you can stick the Ryobi battery underneath. I used a scroll saw to do it - trying to use a Dremel tool was a terrible experience. After cutting the hole, I basically cut out the outline of the tower connector so it can slot into the battery. I added a bunch of mounting holes; use what works. Drill the holes into the bottom of the battery case and mount it using regular wood screws. I superglued the tower to the top. You're supposed to use some nuts/bolts, but I'll see if this works; if not, I'll switch to bolts. My image shows my unrefined model, which I created by gluing/screwing two pieces together. The refined model should be better now with spacing and everything. It's a bit large, but that's just the way it is (unless someone is willing to refine it). Refining will reduce it by a few millimeters only, but it would look nicer. Keystone 209 for contacts I printed this adapter at 20% infill with 0.2mm layer and supports everywhere. To print the tower portion upside down, I only needed supports for the fins/ears and the connector part. You should use supports around the base clip points before installing the Keystone 209 contacts. Before doing that, collapse them a little bit with pliers to get a perfect fit (see photo). Solder your wires onto the battery tabs before sliding them into the tower pockets - otherwise, the heat may damage the PLA (or other plastics). Install the contacts by pressing them over the pockets until they lock into place. Assemble the base and tower using either 4 mm or 6-32 flat head screws and matching nuts. The above instructions were taken from: https://www.thingiverse.com/thing:4129039 V2: I forgot to leave space for the battery tower, so I added that extra spacing. V3: Minor touchups