xbox 360 controller 18650 battery holder

thingiverse

A Custom Battery Holder for Xbox 360 Wireless Controllers using 18650 Batteries https://www.thingiverse.com/thing:110764 Remix IMPORTANT NOTES 1) The voltage will be slightly higher than regular batteries since a charged cell is over 4v, compared to the 3.2v of two AA batteries. This didn't cause any issues except for the ring LED staying dimly lit even when the controller was off, but results may vary and I'm not responsible for damage caused by ignoring this warning. You can use a diode to drop down the voltage by 0.6v, making it just above a regular battery pack. 2) Many 18650 cells don't come with built-in protection circuits, which means leaving them in the controller will drain and potentially ruin or even cause a fire. I'm not responsible for any damage caused by ignoring this warning. You can solve this problem by adding a protection board, just like the diode, or simply remove the battery from the controller and charge it every now and then. Printing 0.25mm layer height, whatever infill you want, but use 1mm walls and top/bottom for extra resistance and drilling capability. No supports or brims are needed. Assembly You'll need 4x M3x10 or M3x16 countersunk screws and 2x M3 nuts, or their imperial equivalents. Holes are 2.5mm, so an M3 will tap into them easily, cutting the threads. The nuts hold the wires attached to the contact screws. To make the springs, use steel wire (I'm using 0.6mm stainless steel wire), coil it around an M8 bolt or similar, leaving a little lead for "soldering" copper wire on. You can't solder to steel but you can coil the copper wire around the steel wire and add some solder to lock it in place. Once this is done, slide the springs inside the slots of the 18650 holder and secure them with hot glue. Slide the wires into a hole (you might need to drill it out) and connect them to the contacts using the nuts. Don't mess up the polarity! Once this is done, just attach the bottom shell to the top shell with hot glue and you're ready to go. You can keep the battery in with a piece of wire between the two holes at the top, loosening it slightly to slide the battery out. There are many holes on the top shell for using various battery holders; the three center ones are 2.5mm ready to be tapped with an M3 screw.