TS100 18V kit / Makita / Bosch with folding support

thingiverse

Here is my collection of 18v parts to use with the TS100. Updated for magnetic latching of the hinge. Feel free to add comments for suggestions and post some makes if you make this. I'd love feedback! This project is ideally suited to someone with tinkering / electronics experience as soldering is involved. I also hold no responsibility for damage to persons or property when putting together this build, and you build at your own risk. A shorted 18v battery can be very dangerous and can lead to fire. I will try and add as much information as I can to help with printing and making these. There are base files attached for Bosch and Makita (at this time, working on DeWalt and Milwaukee). The TS100 is rated at 17W-65W and I haven't seen anymore than around 3 Amps draw in testing. Update on testing - I had our manufacturing department use this set up for a full day of soldering. Managed to get 4 hours continuous use (350c / 5S in firmware) from a Makita 3AH 18v battery. ------------------------------------------- Battery Clips ------------------------------------------------------- Clips for battery should be printed at any layer resolution but I used 0.2. 20-40% infill depending on your requirements and filament type. These should be printed with supports You will have to purchase the inlay spare part from the corresponding manufacturer. Part numbers below - Makita: 643838-6 Bosch: 1609280478 You will also need either right angle spade connectors for Makita or solder on your wires for Bosch. ------------------------------------------- Upper / Stand ------------------------------------------------------- The upper base should be printed the same as the bottom battery clip but with no supports. The stand however should be printed with tree supports. I recommend putting support blocker cubes on the holes for the hinge. Cura automatically wants to put a small amount of support in the hole which can affect fit (See screenshot). The updated parts have provision for two magnets. Mine are printed to be interferance fit but you can glue if required. These are the magnets I have used. They measure 10mm dia x 3mm https://www.jaycar.com.au/rare-earth-magnet-small-pk-4/p/LM1622 **Important** Print the Axle shaft at the lowest resolution your printer can successfully handle with 100% infill and make sure to use a brim for build plate adhesion. ------------------------------------------- Assembly ------------------------------------------------------- Parts Required (supplementary to printed items): • 4x M4 screws / bolts at the lengths required for your particular clip. (I have countersunk the base of the holder but hex heads are fine) • 4x M4 nuts – I use M4 Stainless steel as the hex cut-outs in the clips are designed for them. • Brand specific terminal adapter plate (See part numbers above) • 2x right angle spade connectors • 1m Silicone dual core wire (Make sure it is rated for about 3-4amps) • 1x 2.5mm DC power connector (with long body) • Attach your heat shrink and fuse if required • Assemble the battery clip and upper base with your nuts and bolts. Make sure they are tight or add some Loctite. • Fit the upper stand to the base over the hinge • Trim your axle to a length you like • Slide the axle in and make sure the hinge operates • Put a small touch of super glue on each end. You can also cut on the angle of the hinge and gently massage it into the rest of the part with a soldering iron (don't use super glue for this method. Cyanoacrylate fumes are extremely bad for you) • Insert your washer and affix with either super glue or epoxy • Cut a small piece of foam for cleaning your tip (this will expand when wet) And your good to go! n.b. Don't forget to adjust your TS100 settings for use on a battery. This will prevent running your battery into the ground. I would like to credit / thank these creators for a lot of the starting points for this build: • brandman211188 • GPlatek • bbzed