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Installing a Blank Battery Contact Board in a C6 Pill

Garoq

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Aug 27, 2010
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This is a quick tutorial on how to install one of our blank battery contact boards in a drilled C6 pill.

First, remove the nubs from the sides of the board with sandpaper or a small file:
10856490666_1926ffe562_c.jpg


Next, insert the board, wire side first, into the side of the brass ring with the recess:
10856499386_2dd6e97678_c.jpg


Push the driver board completely into the recess in the ring:
10856442275_f91211c6dd_c.jpg


Solder a small spot on the negative board trace next to the brass ring about 1/4" wide. Ensure that the solder has wetted both the board and the ring:
10856428395_1ee1f32a97_c.jpg


Solder a similar spot on the board 180 degrees from the first spot:
10856489886_2c1cabbeac_c.jpg


Wire side view of the finished subassembly:
10856489796_6f8fb5868f_c.jpg


Place the brass ring & board subassembly, tapered side first, into the recess in the pill:
10856580884_77cd5501ff_c.jpg


Lightly press the brass ring & board subassembly into the pill recess until is evenly spaced above the pill:
10856581104_defc6949f3_c.jpg


Using pliers, gently squeeze the brass ring & board subassembly into the pill recess. Work your way around the pill to push the ring evenly and completely into the pill:
10856581254_760209191f_c.jpg


Side view of the completed assembly:
10856427885_de2d5e80ef_c.jpg


Top view of the completed assembly:
10856770653_8fe7efc283_c.jpg


Another view:
10856581754_bc75895144_c.jpg


Using a DMM, test the negative side of the circuit for continuity. The reading should be zero ohms.
10856490416_ee444935a8_c.jpg


Test the positive side of the circuit for continuity. The reading should be zero ohms.
10856427775_a8a9b56245_c.jpg


Finally, check the circuit for a short. The reading should be infinite or "over limit" ohms.
10856490606_40fd43de96_c.jpg


You are now ready to connect the battery contact board and pill assembly to your driver. I've posted a tutorial here about soldering a driver and pill assembly to a diode, but most of the instructions are similar.

Enjoy! :beer:
 





Garoq

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Joined
Aug 27, 2010
Messages
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Points
83
You're welcome. It's an old post but still completely relevant. Our blank battery contact boards look different now (no longer repurposed blank driver boards but made specifically for the application) and other than that, the assembly and testing is the same.
 




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