How to replace cells in a rechargeable 18V DeWALT DE9095 2.0 drill

My old drill - About to get a new lease of life!

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New cells, with tabs, available from the link to the right: small battery company: Tel: 020 8871 3730 (link at the end)

I bought sub C 2400mAh 1.2 NiCd Tagged Battery 15 pack for 12V (Cost £36.00 in January 2013)

Remove the torx screws from the battery pack, remove the lid and lever the batteries out with a couple of flat bladed screwdrivers.

Keep the battery pack intact so you can copy the connections (!) - this is very important for later on.
I found that it helped to number the old batteries and new ones with a permanent marker.

Make a drawing of your connections and make sure you have a proper circuit eg. positive to negative all the way round.

Arrange your new, numbered batteries leaving the heat shrink on the tabs!!
I found it easier to put the new numbered batteries in the battery casing, as this kept them in the correct shape and position and made it easier to solder.
Start soldering all the batteries together in the correct order. Diagram 2 (Only removing heat shrink when you’re ready to solder!)
Turn over and solder the connections on the other side. Diagram 3
You may need to trim some tabs as some are too long.
Tape can then be wrapped round the batteries to hold them together.
The positive of battery 8 connects to positive post of the plastic insert that goes into the drill handle.
The positive of battery 15 will connect to negative of battery 10. Diagram 1

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Put cardboard back on, with pritt stick, to provide a cushion between the batteries and the case. (I made a new one as mine was broken.)

Insert the positive tab of battery 15 into the holder and solder the tab onto the negative of battery 10. Photo 6
This sits on top of battery 9

On the other end of battery 15 you need to solder a wire onto the positive post of the plastic insert that sits on top of the battery. Photo 8
The other end of the wire will be soldered onto the positive tab of battery 8. Photo 9 and diagram 1

Replace the battery lid and screw shut.
Put your new battery on charge and celebrate that you have reconditioned your drill for less than half the cost of a new battery pack!

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Watch, photo, hearing aid and other small batteries for sale on-line. Free delivery in UK. A bargain camera, button cell or lithium battery. Credit and Debit cards accepted.