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> How To Make A Battery For Your Gizmondo, Using a Sanyo DB-L40
FR4NK5T3R
post Jun 16 2006, 12:39 PM
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Ok here's how to convert a Sanyo DB-L40 Battery for use in the Gizmondo

(IMG:http://usera.imagecave.com/Fr4nk5t3r/picture00002-copy.jpg)

Firstly you need the following:

1 x Sanyo DB-L40 Battery. I bought one for under £7 from here DIGITAL-iSHOP
1 x Gold plated Matrix board from Maplin N97CF £1.99 (Don't use normal copper it tarnishes)
3 x pieces of standard 25swg tinned copper wire about 30mm in length
3 x pieces of 30swg enamelled copper wire or pvc insulated wire about 100mm in length
also insulation tape a sharp knife, some cardboard, a hacksaw, some solder and a fine tipped soldering iron

Step one

Cut a piece of matrix board to the shape and size shown. This can be done by using a hacksaw or by simply scoring along the holes with the knife on both sides and carefully snapping the board with a pair of pliers.

(IMG:http://usera.imagecave.com/Fr4nk5t3r/Matrixcut.jpg)

Step two

Take the three pieces of tinned copper wire and make a small right angle bend on the end of each about 2mm long and pre tin it. This creates a foot to solder to the battery. Stand the battery up in a vice or blob of blue tac and pre tin the three contacts. Don't linger too long with the iron as the case will melt. Now solder each wire to a battery contact as shown so that the wire is not in the middle but towards the edge. This helps to line up with the Giz contacts. Be careful not to short the two outer wires when they are connected as the battery could go bang.

(IMG:http://usera.imagecave.com/Fr4nk5t3r/Batterypins.jpg)

Step three

Carefully line up the wires and slide the piece of matrix board down onto the battery and solder as shown. If you are fairly quick they won't come unsoldered from the battery.

(IMG:http://usera.imagecave.com/Fr4nk5t3r/batterymatrix.jpg)

Step four

Take the 3 pieces of enamelled wire, pre tin one end and poke through the holes in the matrix board where it sticks out. Bend them back to the edge and solder. It's important to keep the main contact area clear of solder as this will ruin the gold plating. Now lay the three wires along the battery and cut to correct length to reach battery pins. They are in the same order i.e. the first wire goes to the first pin, the second to the second pin and the third to the third pin. Pre tin and solder these to the top of the matrix board at the appropriate pin.

(IMG:http://usera.imagecave.com/Fr4nk5t3r/batterywired.jpg)

Step five

Cut a 6mm wide strip of card about 85mm long as shown. Bend it at the 35mm point and stick it with tape to the edge of the battery. This is important to push the battery against the Giz terminals.

(IMG:http://usera.imagecave.com/Fr4nk5t3r/Cardboard.jpg)

Step six

Offer the battery into the Giz and make sure the contacts line up properly. If not adjust cardboard or push matrix board carefully over as necessary. Finally tape the exposed parts of matrix board leaving the three main contacts clear to make contact with the Giz terminals.

(IMG:http://usera.imagecave.com/Fr4nk5t3r/Taped.jpg)
(IMG:http://usera.ImageCave.com/Fr4nk5t3r/clip_image002.jpg)
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Stonker
post Jun 16 2006, 01:08 PM
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Excellent work (IMG:https://gizmondoforums.com/forums/style_emoticons/default/smile.gif)
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marks97
post Jun 16 2006, 01:08 PM
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Gizmondo GOD


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Very nice!!!
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RX Shorty
post Jun 16 2006, 01:32 PM
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Impressive!!! (IMG:https://gizmondoforums.com/forums/style_emoticons/default/smile.gif)

Good work!

Ciao (IMG:https://gizmondoforums.com/forums/style_emoticons/default/cool.gif)
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Spoonatron
post Jun 16 2006, 01:35 PM
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Great stuff indeed. Nice to know that when our Giz batteries die we can make replacement ones (IMG:https://gizmondoforums.com/forums/style_emoticons/default/smile.gif)
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FR4NK5T3R
post Jun 16 2006, 03:25 PM
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QUOTE (RX Shorty @ Jun 16 2006, 02:32 PM) *
Impressive!!! (IMG:https://gizmondoforums.com/forums/style_emoticons/default/smile.gif)

Good work!

Ciao (IMG:https://gizmondoforums.com/forums/style_emoticons/default/cool.gif)


I've gained so much from all the "Softies" in this forum, it's nice for a "Hardie" like me to be able to offer something back.
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gruntyking117
post Jun 17 2006, 01:16 AM
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I'll try that. (IMG:https://gizmondoforums.com/forums/style_emoticons/default/tongue.gif)


http://gizmondo.stu.ac/testintro.wav
Test.
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hagisbasheruk
post Jun 17 2006, 10:30 AM
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Otaku Rocks :)


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Nice
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wigtype
post Jun 17 2006, 05:07 PM
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I suck with a soldering iron, have you considered putting a few on Ebay?
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unhappychild
post Jun 17 2006, 05:42 PM
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REAL TIME WEAPON CHANGE !!!!!11one!!


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QUOTE (gruntyking117 @ Jun 17 2006, 02:16 AM) *
I'll try that. (IMG:https://gizmondoforums.com/forums/style_emoticons/default/tongue.gif)


http://gizmondo.stu.ac/testintro.wav
Test.


wtf.
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FR4NK5T3R
post Jun 18 2006, 09:45 AM
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QUOTE (wigtype @ Jun 17 2006, 06:07 PM) *
I suck with a soldering iron, have you considered putting a few on Ebay?



No that's called a solder sucker! You put the solder on with the iron.

Only kidding!

Yes I have considered it. Would anyone else be interested?
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howser
post Jun 18 2006, 11:04 AM
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I would buy maybe two but then how much would you sell them for.
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FR4NK5T3R
post Jun 18 2006, 09:58 PM
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QUOTE (howser @ Jun 18 2006, 12:04 PM) *
I would buy maybe two but then how much would you sell them for.


I'm thinking about £15
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FR4NK5T3R
post Jun 20 2006, 02:36 PM
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QUOTE (FR4NK5T3R @ Jun 18 2006, 10:58 PM) *
I'm thinking about £15



.......................and you could hear a pin drop!
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gizmondobat
post Jun 21 2006, 11:34 AM
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1800 mAh Gizmondo battery now for sale on e-bay for £14.99. No longer worth risking life and limb making your own lithium ion battery which is highly dangerous.
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FR4NK5T3R
post Jun 21 2006, 12:39 PM
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Thanks Gizmondobat. This is great if you have the back to go with it or you don't mind a bit of gaffer tape on your Gizmondo.

Here's the link http://cgi.ebay.co.uk/Gizmondo-Hi-Capacity...1QQcmdZViewItem
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zektor
post Jun 25 2006, 05:25 AM
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That is cool. I would really like to find ways to make the Giz accept other alternate power...namely rechargable AA batteries. They are easy enough to get ahold of anywhere, and would extend the Giz's life as well. I'll have to look into it...
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puggster
post Jun 25 2006, 08:56 AM
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W0nK3e d0nKEe


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My Points:34, vote for me :) hehe
great work FR4NK5T3R, a rather neat looking prototype (IMG:https://gizmondoforums.com/forums/style_emoticons/default/biggrin.gif)

is there any improvement on battery life ? and does it charge ok ect ?
maby some statistics in a few days once you test it that would be great (IMG:https://gizmondoforums.com/forums/style_emoticons/default/rolleyes.gif)

maby if you decide to sell them in the future there are a few items that will finnish your
batterys off nicely

personaly if i were just gonna use it for my self i would cover it in black tape lol (IMG:https://gizmondoforums.com/forums/style_emoticons/default/rolleyes.gif)
but you probably know that you can buy heat srink tube wrap that you could finnish it with
and could also help increase sales is that you can buy it in lots of colours,
give costomers choice lol just a thought (IMG:https://gizmondoforums.com/forums/style_emoticons/default/rolleyes.gif)

anyhoo great work i hope it all works out for you

cheers puggster (IMG:https://gizmondoforums.com/forums/style_emoticons/default/cool.gif)
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FR4NK5T3R
post Jun 25 2006, 09:56 PM
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QUOTE (puggster @ Jun 25 2006, 09:56 AM) *
great work FR4NK5T3R, a rather neat looking prototype (IMG:https://gizmondoforums.com/forums/style_emoticons/default/biggrin.gif)

is there any improvement on battery life ? and does it charge ok ect ?
maby some statistics in a few days once you test it that would be great (IMG:https://gizmondoforums.com/forums/style_emoticons/default/rolleyes.gif)


I'm not really into doing capacity tests because there are so many different permutations to how you use the Giz. It's basically a 1200mA battery as apposed to the 1100mA Gizmondo battery. I've been charging and using it for a couple of weeks now and it works fine.

QUOTE (puggster @ Jun 25 2006, 09:56 AM) *
maby if you decide to sell them in the future there are a few items that will finnish your
batterys off nicely

personaly if i were just gonna use it for my self i would cover it in black tape lol (IMG:https://gizmondoforums.com/forums/style_emoticons/default/rolleyes.gif)
but you probably know that you can buy heat srink tube wrap that you could finnish it with
and could also help increase sales is that you can buy it in lots of colours,
give costomers choice lol just a thought (IMG:https://gizmondoforums.com/forums/style_emoticons/default/rolleyes.gif)

anyhoo great work i hope it all works out for you

cheers puggster (IMG:https://gizmondoforums.com/forums/style_emoticons/default/cool.gif)


Yes for the prototype I used Capton Polymide tape as it was available and transparent so you can see the battery through it. I've tried heat shrink sleeving and I find it is too thick plus you have to heat the battery up too much to shrink it down. I'm still keeping my eyes open for a suitable black tape that looks professional
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Guest_Tommi_*
post Sep 3 2006, 05:07 PM
Post #20





Guests
lol, try electrical tape.....
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