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DIY Dummy AA Batteries

For electric blasters using UltraFires or similar batteries.

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#1 blacklion

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Posted 27 April 2013 - 02:51 PM

Hey guys! Just wanted to share my method of making dummy AA batteries. I recently ordered some UltraFire 14500 batteries so while they arrive, I decided to make these dummies using only materials I already had.

WHAT YOU WILL NEED
  • Used Duracel (or similar) AA batteries (2 per dummy)
  • Tradewinds 3-Function Light and Laser Pen (or similar metal/plastic tube)
  • Dremel (with cutoff wheel and sanding wheel)
  • Soldering iron
  • Solder + Flux
  • Electrical tape
  • 12 gauge (or similar) stranded copper wire
  • Caliper (or ruler, or measuring tape)
  • Hammer
  • Pliers
  • X-acto knife
  • Sandpaper (220 or rougher)
  • Nitrile gloves (highly recommended)

Very carefully peel the bottom plastic from the used AA battery and using the X-acto knife remove the bottom plate. You will need 2 bottom plates per each dummy AA you want to make.
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Find a tube (metal or plastic) of similar battery diameter, to be used as the dummy's body. I used the bottom part of this Laser and LED pen just because I had a few of these laying around.
NOTE: If you have never used these, i would advise you to buy a few either online or at Walgreens (2x$5). They are very cheap, the circuitry is very straightforward and compact and include 3 batteries. This is what I add to my guns. Write up coming soon.
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Only use the metal bottom part. Save the top part.
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Straighten the AA plates using a hammer and whatever you have available.
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Measure the thickness of the plates so that you know how long the body of the dummy needs to be.
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Measure a real AA battery and write the dimensions. A quick calculation and now you know that the pen shell needs to be cut to ~49.96 mm.
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Cut the shell of the pen slightly longer.
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Carefully grind to correct length.
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Remove the insulation from the tip of the pice of wire you will be using.
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With the tip of the X-acto knife scratch the surface of the AA plates.
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Add some solder to the plate.
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Add solder to the tip of the stripped wire and proceed to solder both pieces together. Note that you should spread the copper wires in order to increase contact area.
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Sand around the ends of the pen shell and proceed to solder it to the plate. Try not to leave any empty spaces.
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Cut the exces wire (at the other side) to appropriate length and repeat previous steps.
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Once done it should look like this.
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Now grind the excess material until a "smooth" surface is obtained. Do this on both ends.
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Once done, add a ball of solder to the top of one side. This will act as the tip on the positive side of the dummy.
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Sand the excess solder from the positive tip, until the desired overall length is obtained.
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Wrap with ET, and you're done!
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I measured the resistance of the dummy and found it to be very small as expected. (This other guy at this other forum using other other materials obtained similar resistance values).
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This is how it looks compared to a regular AA battery.
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It fits perfectly.
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Yes, you could probably buy the dummy batteries off the internet but it wouldn't be as fun. I have not been able to find the resistance value of a real AA dummy battery. If someone has measured it, please share the result as I would like to compare values.

Hope this helps! :)

EDIT: Fixed image links.

Edited by blacklion, 21 May 2013 - 12:08 PM.

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#2 roboman

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Posted 27 April 2013 - 06:42 PM

Nice work!

Instead of sacrificing a pen every time, I'd imagine a piece of brass that's about the same size would work just as well, and you could avoid the internal wire entirely, since brass conducts electricity very well. A piece of heat-shrink would probably look better than e-tape, too.
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#3 andtheherois

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Posted 27 April 2013 - 06:52 PM

This is pretty sweet.

I personally like the "wrap an appropriately sized bolt in tin foil" approach.
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#4 therealnerfjunkies

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Posted 28 April 2013 - 02:58 PM

This is a pretty good idea but it requires too much work. I'd rather get these, get an appropriate sized bolt, put it in the converter and you have a dummy battery.
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#5 Jeo

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Posted 29 April 2013 - 11:35 PM

My method...

________________________________________________________________________

Tools/Materials needed...

Solder and Iron
Drill and an assortment of bits
AA-D convertor/AAA-AA convertor
Small length of wire
Wire strippers
12.7/9.5mm dowell
Something flat and metal (I used the blade of a knife but just about anything would work here)
________________________________________________________________________

The materials in question
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Mark the dowel at the length of a battery.

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Drill a small hole through the centre of the dowel, then counter sink a small recess in each end.

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Feed some wire through the dowel and cut it to length. We want a little over on each end.

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Strip the end of the wire back.

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Place a large blob of solder in the small counter suck recess we made earlier, making sure it has a good connection with the stripped end of wire.

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While the solder is still hot, flatten it out with your flat metal object.

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Insert the dowel into the adaptor case and we're done! You now have your very own AA dummy battery and D dummy battery.

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#6 blacklion

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Posted 30 April 2013 - 12:00 AM

My method...


Looks good too! I wanted to use the AAA-AA converter but since I couldn't find them cheap locally, went ahead and worked with what I had available.

Did you measure the resistance (ohms) of your dummies? I want to compare the available methods with the off the shelf dummy batteries.
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#7 Kronos Nerf Mods

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Posted 30 April 2013 - 05:00 PM

Figured I would just throw this out there:

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They are pretty ugly, but have very little resistance, as they conduct the electricity with normal wire.
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#8 DartSlinger

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Posted 30 April 2013 - 05:58 PM

Figured I would just throw this out there:
*pictures*
They are pretty ugly, but have very little resistance, as they conduct the electricity with normal wire.

What is the metal part made out of? It looks like dimes.
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#9 Kronos Nerf Mods

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Posted 30 April 2013 - 08:55 PM

What is the metal part made out of? It looks like dimes.


Well the wire is metal, and the actual battery shape is 3D printed. No metal, No dimes.
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#10 Jeo

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Posted 01 May 2013 - 11:16 PM

Did you measure the resistance (ohms) of your dummies? I want to compare the available methods with the off the shelf dummy batteries.


Haven't checked but I'd imagine it's entirely dependent on the piece of wire you use.
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