The battery holder is finished! I didn't want to rush things and rather let the glue dry during the weekend. Here are pictures of how I made it, maybe it'll be usefull for some of you
1 - cut these metal sheets as marked (be sure to cut the right ones, one on (+) and one on (-) side, as the arrows pointing)
2 - remove the metal sheets on the other sides
- now I soldered to each one little brass pill for better contact, but this is optional
- prepare two about 12cm long wires and solder blue to (-) and red to (+) sheet. The blue is soldered on top side (as seen better on next picture) and the red is soldered on the inside - it is better for (+) protection against accidental short circuit with flashlight tube or driver
3 - drill hole in the plastic wide enough for the (+) cable, put the cable through and glue both sheets back to plastic holder
- here is detail of how the blue cable is soldered, unfortunatelly I forgot to take image for the red cable, it is soldered from bottom of the sheet
Now on the sides that will be glued together:
4 - cut small groove for blue cable, ideally with A shape so the cable 'click' in - this will help later at gluing
5 - bend the cables as on picture, cut for proper lenth and solder them to parts cutted in first step
6 - clean both plastic surfaces (I used alcohol),
- apply enough glue in the middle of both plastic parts, also coat cables with a little glue
(the glue layer will be about 3mm thick when both parts are glued - the cables are glued in between and their thickness make those 3mm, so the best is apply enough glue in the middle and when both parts are pressed together, glue will fill the space)
7 - carefully put the metal sheets on place, each on opposite holder, (easy because cables are long enough) align cables and press both parts together
- fill the glue where its still missing and remove excess glue
Freshly glued, I used white Mamut glue from Den Braven, holds like crazy and the work is very good with it
While the glue was drying, I also soldered the springs to the contacts
And, final 3s2p holder - just added red/blue insulating tape to the ends to avoid accidental wrong inserting
All parts are the original used in holders, there were only little brass pills added on each end and springs were soldered. I'm very curious how many amps will this modified holder be able to provide. I didn't test it yet but will do it very soon... Now the next I want to do is direct-solder led to custom copper heatsink similar to Match's latest test. If all will go well the heatsink will be made this week!
So this is it for now, will post any update I'll have