Bosch 18v NiCad Tool to DeWalt 20v Max Battery Adapter
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3D model description
Allows you to use DeWalt 20v max lithium batteries on old Bosch 18v NiCad tools. Orienting the battery backward is optimal for the majority of tools like the planer and jigsaw. This adapter seems pretty strong. I've used it a lot and it fits the tools and batteries properly and won't fall out or come apart like other adapters that I tried before finally designing this one. It has a compartment inside for low voltage cutoff or other electronics but I haven't needed to use them yet. They still sell 18v Bosch batteries but I have a lot different cordless tools and it's hard to properly maintain and cycle so many different brands and types of batteries. When my last one died I reluctantly bought Dewalt batteries because they seemed to be the only brand offering their own adapter. So now I'm making adapters for all my tools to use them. It should be noted that large amp/hour batteries could protrude enough to collide with the work surface on certain tools. Modifying the adapter to have a 20 deg. tilt could prevent this but it was deemed impractical.
I used 9 screws that took a size 10 torque bit, approx. 10mm long with 5mm wide heads, and 2 springs about 6mm diameter, and 15mm uncompressed. All salvaged so I have no skus.
3D printing settings
I used ABS. It's not the easiest stuff to work with. Here's what I got to work on an Anet A6 in an enclosure with a glass bed coated with TREsemme hairspray at 100deg, nozzle at 220-230 deg, slowed speed down to 40mm/s, no cooling fan, full Brim, 50% infill. For the top and bottom: .15mm layer height or "normal", full supports over 50deg angle, lines. For the buttons: .06mm layer height or "extra fine", full support lines but increase their density to 50% so they're closer together. Inevitably there will be some warpage and shrinkage and there is some tolerance for that. Naturally there's a bit of cleanup and finishing to do, like removing the brim and burs, before assembly. Start by sanding with a flat surface the mating faces of the top and bottom. Then Pre-drill and tap the screw holes first with a bit and then thread the screws in before trying to attach the top and bottom together or you'll have trouble lining them up. You can use ABS cement or filament dissolved in Acetone to make repairs, secure the contacts or coat stripped holes. You'll need to do some filing to the buttons and all the surfaces surrounding them so they slide freely and extend outward far enough to grab the tabs within the tools. Pay particular attention to how level or square they sit in relation to the the top half. Some filing will need to be done with the halves assembled without the buttons inside. The curved bottom in the base that they sit in, because printed upside down, will need a bit of filing too. The wires are soldered to the terminals, fed down through the top, and then pressed in. ABS cement can be applied if they're loose. Check the polarity, the battery and socket are opposite each other.
- 3D file format: STL
- Last update: 2020/09/30 at 00:41
- Publication date: 2020/03/07 at 00:56
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