I'm rebuilding a bike headlight battery pack with new cells. The factory pack has connector strips spot welded on to connect the cells.
I tried prying these strips off but they are pretty mangled. Could I get some recommendations on where to get new strip? I need 5mm and 3mm wide. Both measure .08mm thick. I only need about 6" of each so I don't want to buy a huge roll. Thanks!
I will be soldering by hand but I assume this type of strip will work just fine for that. If there is a different product that's recommended please let me know.
Liion Wholesale has lots of nickel strips in various flavors and if you search nickel battery strip on amazon there are tons there as well (aliexpress too). I don’t think any variance in the quality of the strips will matter so much for a light but if you were doing a high power pack like a scooter or e-bike then you’d want to be sure to get the high quality stuff. Liion will always have quality/suitable material, amazon and aliexpress you can’t always be sure. Digikey may also have some of this but I’d bet their price+shipping won’t be so competitive.
If you’re soldering by hand, use “pre-tinned solar bus tabbing” wire.
Advisability of this technique is controversial. I’ve done it. I wore good safety glasses. It’s not especially difficult to get a cell to violently vent flame with a soldering iron.
Have you ever tried soldering nickel-plated wire or tabs?
If not then consider using AWG 20 silver-plated copper wire with some low temperature solder such as Roses alloy. This alloy is recommended and used by Barkuti.
Pre-tin the cell tops and the wire, then a quick joint can be made with a minimum of heat into the cell. Use flux if needed to pre-tin the cells.
If you are skilled and quick at soldering then regular rosin core tin solder can be used with the same technique.
