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Discussed in this article : Step by Step Instructions on How to Splice a NiCad Battery with Existing Battery Connector

Tools Needed:

  1. Crimping Tool. It is suggested using a four-way wire crimper to be able to crimp and splice.
  2. Butt Connectors. Insulated butt connectors work best.
  3. Turn off the circuit. Never attempt to work on a live circuit. Rather, turn off the power at the panel and follow lockout/tagout procedure.

1. Preparation:

  • Before you begin, make sure you have all the necessary tools and equipment in a well-lit and ventilated workspace.
  • Disconnect any power sources and ensure you are working in a safe environment.

2. Removing the Old Connector:

  • Start by cutting the connector from your existing NiCad battery. This connector will later be connected to your new battery.
  • Use the wire stripping tool to carefully cut the wires from the old battery, making sure to leave some slack for the splicing process.
  • Dispose of the old battery properly according to local regulations for hazardous waste.

3. Stripping and Preparing Wires:

  • Examine the wires you've cut from the old battery. You'll find a red wire and a black wire. These wires will be spliced to your new battery.
  • Use the wire stripping tool to strip the insulation from the ends of both the red and black wires. Choose the appropriate wire gauge setting on the stripper to ensure proper stripping without damaging the wires.
  • Twist the exposed strands of each wire gently to keep them together and prevent fraying.

4. Splicing the Wires:

  • Now you'll attach the butt connectors to the wires. Insert one wire into each end of the butt connector.
  • Use your crimping tool to crimp the edge of each butt connector securely onto the wires. This will create a strong and reliable connection between the wires and the connectors.

5. Preparing the New Battery:

  • Prepare your new NiCad battery for splicing in the same way as before. Strip the insulation from the red and black wires on the new battery, and gently twist the exposed strands of each wire.

6. Connecting the New Battery:

  • Take the new battery and match the red wire from the battery to the red wire from the connector. Similarly, match the black wire from the battery to the black wire from the connector.
  • Make sure you do not mix up the wire colors, as this could lead to incorrect connections.

7. Finalizing the Splice:

  • Insert each wire into the opposite end of the butt connector where the corresponding wire is already attached.
  • Use the crimping tool to crimp the edge of the connector onto the wires, ensuring a secure connection.

8. Testing the Connection:

  • Gently pull on the wires to make sure they are securely connected to the butt connectors and the battery.
  • Ensure there are no loose connections or exposed wires that could cause a short circuit.

9. Safety Check:

  • Before using the spliced battery, double-check all connections, wires, and components to ensure everything is properly secured and insulated.
  • If everything looks secure and safe, you can now use your spliced NiCad battery.

Please note, this process involves electrical components and potentially hazardous materials. If you're not comfortable with this procedure or lack experience, consider seeking assistance from someone with more expertise in electronics and battery-related work.