FrSky X-Light battery screw caps

thingiverse

Let me start off by saying this mod is definitely not for the faint of heart. I saw there was a clear need for a more secure battery cap with the new FrSky X-Light remote, so I designed one to hopefully help out a few fellow pilots who are just as passionate about safety as I am. Below is a step-by-step description of the modification. Parts are printed with PETG, which has proven to be an ideal material for this project. You will need one item that isn't included with the controller: a very thin piece of sheet metal, like you would see in a simple soda can. You will need to cut two small round plates the size of a quarter. I tried to design this mod with all stock parts, but using this extra piece of thin metal was unavoidable - but easy to obtain. Here's how it's done: 1. Print out the parts (I know that was a given). 2. Remove the old battery holders and wiring from the controller. 3. Unsolder the wire from the battery terminal at the back end of the battery holder. 4. Remove all wiring and metal terminal extenders from around the old battery holders. Also remove the back terminal plate and spring. 5. Completely remove (desolder) the spring from the terminal back plate of the previous step and save the springs for later. 6. Remove the hardware from within the battery caps. Keep the screws and spring plate. 7. Completely remove (desolder) the spring from the battery cap spring plate. You won't be needing these springs again. 8. BIG STEP HERE: Now take the spring from the back battery terminal (the first spring you removed) and the spring plate from the battery cap terminal, and solder them together. You will need to remove a small section of the bottom of the spring (only 1/2 to 1 coil) just enough to where the spring fits nicely on the center circle of the battery cap terminal spring plate. You will also need to bend the bottom of the spring just a bit inward where you cut the coil from the base of the spring to help make it fit on the plate (This step is critical to give the proper spacing and tension for the new screw cap). 9. Place the back battery terminal plates into the new 3D printed screw type battery holders (Yes, without a spring). Solder the wire from the wire harness back to the plate. Don't forget to use some heat shrink. 10. You will need to cut two small very thin metal plates 20mm in circumference to place inside the new 3D printed battery cap inserts. Use a soda can and face the metal side up as you place the metal plates inside the caps. Drill two holes in the plates to match the screw holes in the cap inserts. 11. The battery terminal extenders that extend to the outer edge of the battery holder need to be bent 180 degrees to lay over the edge of the battery holder, just like the pictures show. This will ensure a snug and secure fit. 12. Install the battery terminal extenders and wiring to the new 3D printed screw type battery holders and install them into the controller just like the old battery holders were installed. 13. This is another big step: you will need to modestly dremel out the inside of the battery cap covers to make room for the screw type inserts. DO NOT DREMEL TOO MUCH OUT!! You can easily dremel through to the outer surface if your not careful. Take your time and go slowly, just like I did. 14. Screw the 3D printed screw type inserts along with the spring and spring plate you created on top of the metal plates into the battery cap covers (See pictures). Make sure the right and left sides are in the proper battery cap covers with the top of the L or R pointing towards the top of the cap. 15. Enjoy not worrying about your caps coming off!