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Old 05-11-2013, 05:18 PM #1
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Exclamation Tutorial I needed a AAA spacer

Tutorial
How to make a dummy spacer for use in a 2xAAA pointer when using a 10440 Li-ion for about a buck
Things you need
A PILOT easy touch fine pen.
Fine saw or serrated knife
Aluminum foil 6x3 piece
AWG 18 solid copper wire or multi strand
Small flathead screw driver
Large driver with a square bit
12x12 piece of cloth
120 grit emery
Drill or Dremel like device
1mm drill bit
Black sharpie

Take the pen apart and cut a 43mm piece off the clear piece. Use the threaded end

Sand the cut end square

Cut 1x6 strips out of the foil, fold and lightly twist the foil to fit

Using the small screwdriver push the strips of foil into the pen

Every 3 pushes pound the foil to compress it. s
When you get halfway, fold the cloth and put the piece on it and realy pound on the driver. This will make the foil extend past the edge of the tube.

When you get to the last strip be sure to leave a tab to fold into on the strip before it.

Make it as compressed as you can, dont use a hammer or you will crack the piece. It should look like this

Next put the emery on a flat surface and sand down the end that you put the foil in,not the end that the foil protrudes from. Do this till the piece is 42.28mm or as close as you can, a little longer is better than short. Sand any rough edges and make sure the foil wont touch the side of the case when used.
Almost finished

No pics of the drilling, I dont want aluminum dust in the house
Drill a hole the length of the piece in the center or close to it.
Slide the bare copper wire through the piece cut it 1mm out from each end.
Put it on a hard surface and pound it flush with one end and remember one end sticks out slightly.
The copper wire is needed as the aluminum has about 2 ohms of resistance because of multi contact points. Even if you use a single piece of foil this will still happen.
Now paint it with the sharpie and youre done.

This all took about 25 minutes
This one gave a resistance reading of 0.01 Ohms
When you use it put the sanded side towards the spring to be sure to make good contact.
I did it this way ,as it was all I had on hand



6/16/2013
UPDATE
The unit works fine, but after reading the posts below, I realized the German in me was coming out.
I needed another one so this time I took 12AWG cord cut it to length 4 pieces, striped off the insulation about .100 on each end. Taped the four together and pushed the exposed wire into the center area. works fine, took 5 minutes and cost les than 20 cents.

here's a pic



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Old 05-11-2013, 05:29 PM #2
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Default Re: Tutorial I needed a AAA spacer

Good use of what you had on hand, but I much prefer something a bit more solid in there

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Old 05-11-2013, 05:35 PM #3
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Default Re: Tutorial I needed a AAA spacer

I cut a wooden dowel to length. Use a piece of wire to span the length and fasten it at either end with a brass tack. Costs <$5 for like 10 of them, and takes maybe 5 minutes to make.
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Old 05-11-2013, 05:41 PM #4
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Default Re: Tutorial I needed a AAA spacer

Ah Ok
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Old 05-11-2013, 05:55 PM #5
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Default Re: Tutorial I needed a AAA spacer

For either AAA or AA size, I just cut off a bolt to length and then use some heat shrink for the outside insulation
You could even get away with simply wrapping the outside with electrical tape

Above AA size, I use the dowel and wire technique or get an actual dummy battery

Peace,
dave
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Old 05-11-2013, 08:42 PM #6
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Default Re: Tutorial I needed a AAA spacer

Nice tutorial. I have used a piece of metal rod in the past, inserted inside a marker pen. Heres a pic of it:



Actually made it to test some ebay pens with a single 10440. +1 for the write up though!
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Old 05-12-2013, 10:34 PM #7
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Default Re: Tutorial I needed a AAA spacer

I've used a metal rod and some heat shrink tubing in the past for some of my spacers. I still use these in some of my lasers:
CR123 Battery Spacers
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Old 05-14-2013, 05:47 PM #8
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Default Re: Tutorial I needed a AAA spacer

I just cut a PC power cord to length, put self-tapping wooden screws in both ends. Probably adds a decent amount of resistance, but for a device that is looking for 3V and seeing 4.2V, maybe is not such a bad thing.
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Old 05-14-2013, 06:15 PM #9
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Default Re: Tutorial I needed a AAA spacer

Quote:
Originally Posted by BShanahan14rulz View Post
Probably adds a decent amount of resistance, but for a device that is looking for 3V and seeing 4.2V, maybe is not such a bad thing.
I was thinking along those lines too," am I killing these cheap pen lasers with these batteries?" So I just did a test, I hooked one of the pens to a new 9v battery and ran it for a timed 3 1/2 minutes. It got fairly warm, but not to were I would say hot. Still runs fine on three volts. So I think we can getaway with using 10440 batteries in our pens. It may shorten their life spans though.
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Lasers
MSD 303 808nm 256mw/converted 532nm
M who knows 405nm 15mw
Qtech 405nm 95mw with Pmans focus mod
Ebay 405nm 135mw and 12mw pens
405nm Pman special 35mw made from parts he sent me.
Fast Tech 405nm 107mw
Rick Trent 445nm 2.7w Grey host
1st build 450nm PLT450B C3/ YZ-C55 145mw
NDB7675 462nm 1.8 w
515nm 130mw NDG4216
Pman special 532nm 114mw
Ebay 532nm 12mw and 13mw pens
635 ebay pen 5 mw
Qtech 650nm 100mw with Pmans focus mod
SFCR-200 650nm 290mw
Melles Griot P-50 632.8 nm 1mw HeNe
Melles Griot LHR-201-372 632.8 8mw HeNe
405nm BDR-209 800mw custom heatsink and focus by FP
GPT Laser-gard goggles
Noir ARG #60 goggles
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Old 05-30-2013, 12:27 AM #10
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Default Re: Tutorial I needed a AAA spacer

Fattech has extremely cheap AAA and AA spacers. 2 for 89 cents I believe
Have made plenty of my own but have never seen them cheaper than Fasttech.
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Old 05-30-2013, 12:36 AM #11
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Default Re: Tutorial I needed a AAA spacer

that's true Pman, I think that that is better than A homemade one and more reliable.
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Old 05-31-2013, 08:22 PM #12
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Default Re: Tutorial I needed a AAA spacer

How long does it take to ship a homemade spacer you made to yourself? I think fasttech takes longer than a few seconds to get to you.
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Old 05-31-2013, 08:54 PM #13
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Default Re: Tutorial I needed a AAA spacer

pman, i looked on fasttech last night or the night before for spacers but didnt find anything under $5 iirc, have any links?
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Old 05-31-2013, 09:23 PM #14
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Default Re: Tutorial I needed a AAA spacer

I'm happy to report that after hours of use; both spacers are working great with 100% reliability.
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Old 05-31-2013, 09:50 PM #15
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Default Re: Tutorial I needed a AAA spacer

I've made plenty of spacers from magnets and bolts that I then use shrink tubing over when I've needed too but now that I've found an extremely cheap source for them I just stock up so I don't have to make them. Never seen anything cheaper and it still says free shipping. Suggest you buy a bunch so you have some stock of them. I'm all for ingenuity but I would rather not make them when I can get ones like these.

Why you didn't find them is becuase they are in 2 different spots and are not called spacers They are called "placeholders" I like the yellow as you will know at a glance that they are dummy cells.
2 Batteries (Battery Feature: Dummy Placeholder) at FastTech - Worldwide Free Shipping
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4 Batteries (Battery Form Factor: AAA (Placeholder)) at FastTech - Worldwide Free Shipping
4 Batteries (Battery Form Factor: AA (Placeholder)) at FastTech - Worldwide Free Shipping

Code BLF always works for me at 5% off.
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Old 05-31-2013, 09:56 PM #16
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Default Re: Tutorial I needed a AAA spacer

ahhh i search aaa spacer, aaa dummy, aaa EVERYTHING! lol thanks for that +1 when i can

EDIT: guess ive spread enough love to give you some more so added
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Custom Titanium PL520- stable 80mW



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