Building a battery the old school way

[RC10th]

I bought a handful of Sanyo NiCd's to play with and decided to make a couple batteries. You could easily make a vintage looking pack for a runner or even just for display. The only downside is the cost involved is pretty high, ie roughly $30 just for the decals for one 6 cell pack.

I made a 4 cell for a specific project but a 6 cell pack would be no different.

Start by shrinking the cells in a protective sleeve, the sleeves allow you to break apart the pack later without damaging the cells original shrink wrap.

Next glue all the cells together, this packs cells are spaced apart a little bit as it was made to fit a NiMh battery tray.

[RC10th]

Before there were battery bars we used braid.... which is probably still superior to a bar to be honest.

All soldered up

[juicedcoupe]

A couple things to add.

Before tinning the battery ends, I scuff them with a flapper wheel on a Dremel.

And be sure to glue both sides of the pack or it might curve. Or it could just be the glue that I used (E6000?)


If needed, Integy still makes the jigs for pack building.

[RC10th]

Yes, scuffing the ends of the cells is advisable. Some cells had a coating in which you physically could not solder to and had to be removed. The solder flowed out ok on these cells so I didn't bother with that step.

Definitely glue both sides, it increases the pack rigidity tremendously.

Those integy jigs also make great display stands for loose battery cells.

[TravelinTravis]

Nice build!! You can still buy brand new 2500mah Panasonic SCR cells (Super SCR's), plus there's a good seller providing all the re-wraps (customized if you like) to match'em to OG red Sanyo cells. Actually, all in...about the same cost as bitd for a race pack. Braid...not bars=Nice!

[coxbros1]

Nice build!! You can still buy brand new 2500mah Panasonic SCR cells (Super SCR's), plus there's a good seller providing all the re-wraps (customized if you like) to match'em to OG red Sanyo cells. Actually, all in...about the same cost as bitd for a race pack. Braid...not bars=Nice! 20240308_153331-min.jpg 20240311_131824-min.jpg20240331_150030-min.jpg20240401_130852-min.jpg20240401_131248-min.jpg

Nice work!....I found some really nice "gold bars" in the States....nicest I have ever used...braids are nice tho!

[TravelinTravis]

Nice build!! You can still buy brand new 2500mah Panasonic SCR cells (Super SCR's), plus there's a good seller providing all the re-wraps (customized if you like) to match'em to OG red Sanyo cells. Actually, all in...about the same cost as bitd for a race pack. Braid...not bars=Nice! 20240308_153331-min.jpg 20240311_131824-min.jpg20240331_150030-min.jpg20240401_130852-min.jpg20240401_131248-min.jpg

Nice work!....I found some really nice "gold bars" in the States....nicest I have ever used...braids are nice tho!

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Silver plated copper braid=lower resistance. But, for looks, the gold bars are nice!!

[RC10th]

Nice job on those batteries, I tried to buy Panasonic 1700 SCR's but they were discontinued. Are those genuine Panasonic cells?

The green cells were sold as Sanyo 2500 SCR's. I must say it was fun breaking out the old pack building stuff. Like most people I threw away all my old packs and now wish I kept them.

Shrink wrap is easy but If only someone made cheap stickers.... still need to find some yellow 1700's..

[TravelinTravis]

Nice job on those batteries, I tried to buy Panasonic 1700 SCR's but they were discontinued. Are those genuine Panasonic cells?

These cells were sold as Sanyo 2500 SCR's. I must say it was fun breaking out the old pack building stuff. Like most people I threw away all my old packs and now wish I kept them.

Shrink wrap is easy but If only someone made cheap stickers.... still need to find some yellow 1700's..



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I think Panasonic bought the Sanyo battery biz a while back. But it seems there is still some old stock Sanyo floating around. The ones I got are "branded" Panasonic...but these days, who knows...probably made in China. There's some cool info on that here: https://www.master-instruments.com.au/category/sanyo-batteries-chargers/1458

Which glue did you use? I like how clear and even you laid it out on both sides. I was afraid of burning the wrap with the gun tip. I did a small amount to tack the cells in the middle, then laid it on thick on the backside...and my glue came out more white than clear, even though it was sold as clear. Your solder skills held up better than mine too....just enough solder for the joint and very clean! Makes me want to go back over and reclean the excess flux I laid down.....and excess solder for that matter Yours motivates me to do better on the next sets. What solder did you use? (60/40 @ .050dia. here)

Did you use the labels from Cesar Velayos Enriquez? His quality and price was great for mine.....he's based in Spain and I've seen someone do his 1700SCE kit...came out nice!

[RC10th]

I used to use Shoo Goo back in the day or CA glue, with Shoo goo hard to find here I used Selleys Quick Fix Ultra Repair. I'm pretty happy with it as it's thick enough not to run out, it's clear enough, it's slightly flexible and strong. Plus the nozzle is a good size. The trick I found for a good bead was to wait a second or two after each bead before applying the next bead. When you finished one bead and stopped squeezing the tube would suck a bit of air back. If you applied the next bead too quickly it would put the air bubble in the bead.

Your packs look great, I wouldn't worry I just used standard 1.0mm 60/40 lead solder and a cheap 80w iron. I tinned all the battery ends and tinned the braid. I was pretty conscious about not to put too much heat into the braid or it would have melted the shrink.

I haven't used any labels yet but I'm sure I've seen a post here somewhere on those decals you used. The modified text is cool, subtle but accurate. I would love to make a couple of period correct looking packs.

[coxbros1]

MCI has Sanyo battery labels and they look excellent...plus they have 20% off this weekend...u will need yellow or red shrink depending on which label u pick..then go clear over that...it's a 3 step process but looks excellent...pic about 4 post above this are the MCI labels

[TravelinTravis]

MCI has Sanyo battery labels and they look excellent...plus they have 20% off this weekend...u will need yellow or red shrink depending on which label u pick..the go clear over that...it's a 3 step process but looks excellent...pic about 4 post above this are the MCI labels

Love MCI, great selection and fairly open to customizing! What I liked about Cesar 's was that they come with the label (fully customized or standard), the yellow or red shrink and the clear for each cell. A full service kit in one order.

[coxbros1]

MCI has Sanyo battery labels and they look excellent...plus they have 20% off this weekend...u will need yellow or red shrink depending on which label u pick..the go clear over that...it's a 3 step process but looks excellent...pic about 4 post above this are the MCI labels

Love MCI, great selection and fairly open to customizing! What I liked about Cesar 's was that they come with the label (fully customized or standard), the yellow or red shrink and the clear for each cell. A full service kit in one order.

I totally agree..i actually have both kinds...after buying the red/yellow/clear shrink wrap...both are identical in quality but done in different ways

[RC10th]

Mci decals are good, but that full kit with both heat shrink and labels is nice. Is he still selling on ebay?

[coxbros1]

Mci decals are good, but that full kit with both heat shrink and labels is nice. Is he still selling on ebay?

U can contact him personally thru messenger..hit me up if u need contact info