DeWalt Battery Box

thingiverse

Hiya! I have designed 6AH battery pack for my Dewalt DCF880 impact wrench. I used 10 X LG HG2 18650 batteries. 1 X Dewalt PCB (google'it) 1 X 5S2P 50A BMS 1 X DC Jack There was no upper case on thingiverse so designed my own and uploading here for anyone looking to built their own pack. It's not the best but it works for me. Please keep in mind that li-ion batteries are dangerous if you don't know what you are doing. It's also not a rocket science so please do your own research. BMS works in the battery case. So it is responsible to charge all cells equally up to 4.2V each and 21V total.(5 series 2 parallel) Normally the BMS board is inside Dewalt original charger units but I feel that way more practical. There is also dewalt PCB board inside of the case. The pinouts make it easier and PCB also protects the batteries from getting low voltage etc.. So there is two 10K NTC sensor inside the case. You can always change this design to your needs. I have remixed it with "Parametric Rugged box" design from thing:4757317 I have added Fusion 360 file and stl. You can use his box and size it to your needs than combine the uppercase of my design. There are four M3 imbus(DIN915?) bolts that keep the cases together. You can always change it your needs. If I would have long screws I would hide the screws inside the battery case but all changes the case size so I thought M3 bolts enough for the job. The original battery is 170$ + 50$ you need dewalt charger. This has costed around 70$. with quality LG HG2 batteries. Keep in mind that this is not for professionals. This box is not injection mold so I guess it would fail at first drop. I don't use the wrench all day long and it is feasible for me.