WEBVTT

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like many of you we've spent a lot of money on batteries over the years these

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red bricks for our cameras for example cost a whopping

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350 dollars a pop but that isn't even the biggest problem

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with them you see even rechargeable lithium batteries are consumable in a

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sense after a few years of regular use this guy right here gets us a whopping 20

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minutes of battery life that's on a good day which got us

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thinking the housing's still fine the battery

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management system or bms which handles charging and safety that's fine too so

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would anything prevent us from just swapping out the tired cells inside

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saving us some money and keeping needless e-waste out of the landfill

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well you've already seen the title of the video so i think you know the answer

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to that but what you don't know is just how deep this twisted rabbit hole goes

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or who our sponsor is i fix it though in fairness you might

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have seen that one coming is the battery in your device not lasting as long as it

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used to looking for a new project ifixit has you covered stay tuned to the end of

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this video to learn about their battery replacement kits

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let's get this out of the way while we have dabbled in it before diy battery

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repair can be very sketchy especially with lithium cells and we would strongly

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recommend leaving this sort of work to a professional but the difficulty of the

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work is only part of the problem let me show you what i mean

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most lithium-based packs have three basic components a case to protect the

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sparky bits the pack itself made up of individual cells they are 18650s in this

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case and a battery management system or

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bms the bms is the brains of the whole

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operation monitoring and controlling the charge and discharge rates of the

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connected cells now good ones will contain a host of

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safety features like overcharge protection over current protection short

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circuit protection and the like meaning that they act as your main line of

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defense against catastrophic failure but they aren't the only one the second

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safety is built right into the cell itself in the form of a pressure relief

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vent that it's right here on the positive terminal it's designed to vent

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the waste gas that's generated by internal short circuits that naturally

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occur as the cell ages this prevents the cell from pressurizing creating an

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explosion hazard you've probably experienced cell bulging or expansion

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before if you've got a really old laptop or phone it's a similar idea except that

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18650s have a rigid outer housing which

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won't just puff up so with all that out of the way

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this doesn't look so hard let's head to the shop

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since our original intention was to replace the cells inside many of our

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aging battery packs not just make a video about it we snapped up this beast

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of a 30 kilogram spot welder off of craigslist for about 150

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seemed like a good investment but it didn't have the correct leads on it for

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battery spot welding so 70 dollars worth of amazon shopping later and we've got a

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pretty solid spot welder at our disposal we'll have a link down below to the

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leads that we used here and compared to our diy lead acid battery spot welder um

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so far this is working a lot better before we begin let's talk safety

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precautions we've got our fire extinguisher though that's unlikely to

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do much of anything with a lithium fire so we've also got our fire safe

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workstation here with a fire brick that we'll be doing our actual welding on

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gloves and tongs in case we actually need to handle a ruptured cell a sand

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bucket with additional sand to dump over top of it our fume hood as well as

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a pre-propped door for us to take that sand bucket and rip it outside in the

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event that we need to get rid of it next up let's talk about preparation for our

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pack because we have multiples of these red battery packs we actually

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pre-disassembled one for you guys so that we can get going right away but the

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process is simple you just want to desolder the leads that run between the

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bms and the battery pack itself which includes the power leads the balance

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charging leads which are these guys right here as well as this thermistor

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which is going to monitor the temperature of our pack assuming that we

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are able to actually reassemble it with the new bms one other critical safety

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measure is disposal of our old cells we're going to go ahead and cover up all

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of the contacts with something non-conductive like electrical tape and

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put it into our sand and you might be thinking to yourself well gee Linus that

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pack probably only has one or two bad cells in it why don't you just swap

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those out with good ones no we don't do that we never ever do that there's lots

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of electrical engineering reasons not to do it don't

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do it all new cells of course getting your hands on new

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cells is not always the simplest thing ever and you need to make sure that you

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do your due diligence to ensure that you're getting genuine cells rather than

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counterfeit ones which can have issues with reliability capacity and safety we

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picked these up from a local vape shop that we have enough of a relationship with to trust and what collin's doing is

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he's checking them not to make sure that they're genuine but rather to make sure

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that they are all at a similar enough voltage that when we go and

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spot weld them together they're not going to suddenly

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equalize yeah and as good we did that because i

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found five cells that are low so these are 3.2 volts where everything else is

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3.491 depending on how long it's been sitting

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in inventory it might have drained more or less

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and we don't want that our next order of business is to arrange

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the cells in exactly the same orientation before we spot weld them

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together and there are a number of ways to do this you can get these little

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spacer kits off of amazon but unfortunately for us if we compare to

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our assembled pack these leave a space as advertised and

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the original pack does not so we might have to improvise a little bit if we

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want to try to fit our battery into the old housing uh one idea we had was to

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sacrifice one of our batteries and use it as a kind of holder

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here we go for our new cells and then

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pop it out when we're done maybe cut it away while we while we spot weld it i

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don't know another complication that we have to overcome is that we are using

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generic nickel strips there we are make sure you're using

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genuine nickel by the way while red is using obviously some pre-cut ones that

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look a little bit different what do you lean towards colin

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using this boy as a as a holder i think

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we should snip it in half yeah that way we can solder the top side flip it over

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and solder the bottom side while still having support on both sides i really like it let's run it through the bandsaw

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so these are all positive terminal up

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boop boop oh this is gonna work okay

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i think what we're gonna do is more tape we're gonna put them on and then yeah

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and then we'll wrap them and then i think we're in really great shape column

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was like i don't think we're gonna fit this back in the original housing and

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i'm like i wanna try my life's in your hands colin actually all of our lives

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are in your hands Linus all right

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that's not good i'm kind of imagining that i hold this and you wrap the tape

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there we go i have seen dumber things now at this

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point we could start laying down our nickel strips and spot welding everything together but if we make even

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one mistake we are a evacuating this room and b starting our project

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completely from scratch so we want to go ahead and do some test welds now we got

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this all dialed in for a single layer of nickel strip over a

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test cell by the way shout out to the vape shop again for

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giving us a bunch of testers here but what we haven't tried is two layers so

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i'm gonna play around with this a little bit and see if we can get a nice clean

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spot weld on some of our test cells here for spot weld there's a little

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bit of spring tension in this see we want that spring to go down then we're

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gonna go ahead and

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it's definitely on there let's grab another one and let's try two layers you

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should usually do two hits i oh oh i will i will i will don't worry so we're

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doing a weld heat of 690 a ramp speed of three and we think this means 14

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milliseconds let's see how it handles two layers at our current setting i

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think it will be fine you know what i don't think we have to

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change anything colin oh no it popped

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okay try again just uh clean up the tip

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okay now do that 32 more times

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okay this is pretty sweet i'm having fun now this is where things

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get a little bit interesting we're about to do our second layer

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uh colin you want to have a look at this and see how it's going i need a clipboard so i can grade you yeah thanks

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it looks like a battery pack this is the part i'm most nervous about because we

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need to do four cells in a row and this is where we're first going to connect

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positive and negative terminals so this is where we find out how collins uh

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measurements went hoping for no sparks no sparks colin yay you sound

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less enthusiastic than me were you hoping for some sparks the thing about

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super high current is that it doesn't just melt your nickel and your cell

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together it also melts your tips if they're not great tips you know what

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maybe we won't have the link to where to buy these down below they're really not that great okay great i'd also like to

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take a moment to point out that i'm a total amateur at this so if you're

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looking to actually build your own battery packs there are lots of other

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better resources out there

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yep sounds a matter of time ah fudge

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well we popped one oh

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i think i didn't clean the tip often enough well that was a bummer but the

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good news is the video is not over we had a backup plan because we knew going

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into this that lithium batteries are much much more volatile than the nickel

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metal hydride batteries that you might find in your parents old power tools not

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only are the cases much thinner which improves power density but makes them

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more susceptible to rupturing but the lithium inside them is

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chemically much more reactive you guys have probably seen the handful videos on

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the news of electric vehicles bursting into flames that's a lithium battery

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fire and it is no joke not only are they essentially unextinguishable but the

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smoke they emit is toxic too we actually dumped more sand on that and moved it

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away from the door next to the concrete wall there will be no fire there

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so here is what our backup plan is rather

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than trying to tackle a 16 cell pack we're gonna take one of our smaller sony

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style batteries which has just four cells and uh try to rebuild this one the

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silver lining in all this is that now you guys get to see the entire process

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so there you go we've pulled the housing off of the bms here i'm sure all of the

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like diy ebike battery folks are

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have already left their comments wow they're using

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really pin or nickel strips on look at this the minimum possible amount of

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nickel was used backup sand bins right here yeah we got it all right thanks

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colin anger level it's

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so high right now

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well we're down to four matching cells so this will be our last attempt are you

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guys ready to go again yeah i've got a good feeling about these batteries

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what we need to check now is if

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my leads are going to line up with the bms though this guy is going to go here

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and this guy is going to go here so i'm just going to trim those down here we go

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and then i'm going to double check again to make sure i snip off the right part

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i'm okay i'm okay boys you know what now's a good time to throw it into the

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housing then tell me something david yep would you put this pack in a camera do i

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own the camera is it your camera it's my camera uh maybe

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and this is where we bunged it up last time

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do you believe i believe

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sandpaper between yeah you better believe it

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two more strips and then this one this last one here

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actually needs to be quite a bit longer do we got this guys

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theoretically that's it where's the multimeter we should all see seven volts

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here we go boys better have seven folds 6.98 we're short

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kidding kidding kidding i just want to cut away this little square here wraps i

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cut away more of it than i had meant to there let's solder a wire to it

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we had a mishap with our first bms and the snips

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and unfortunately when i saw the spark i

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kind of jerked and moved fast and i'm not sure

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whether the spark was from shorting the battery or shorting the bms so we might

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have killed the bms which means that

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we had to go find another sacrificial battery which was also on its last legs

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anyway and we're going to use that bms so i'm

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just going to go ahead and solder that guy what do you think guys

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much higher chance

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nothing this time i'm surprised that's as good as you can get like yeah there's

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nothing we didn't do anything wrong this time check the pack voltage the battery

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7 volts all that means is that these pads are definitely connected please

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tell me this is a cheap light it's a monitor it's not cheap oh it's

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that's it this time i'm sure we did everything

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right the pack is assembled correctly the bms was it went straight out of a

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working one onto ours i'm

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really surprised this didn't work actually point of clarification i'm

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furious but not surprised let's talk about that we discovered in

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our initial research for this project that even if we had successfully welded

00:14:07.440 --> 00:14:13.920
together a battery for this red brick it wouldn't have come back to life and

00:14:12.240 --> 00:14:18.560
the reason for that is because battery manufacturers are us

00:14:16.399 --> 00:14:22.160
there are multiple tiers of anti-right to repair behavior one of the simplest

00:14:20.639 --> 00:14:27.040
is mechanical obstruction where manufacturers use brittle plastic glue

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single-use fasteners and other similar strategies to make repairing their

00:14:28.320 --> 00:14:35.360
devices impractical sometimes this is just plain not caring about the user of

00:14:33.440 --> 00:14:39.600
the environment while other times this happens for malicious reasons like

00:14:37.279 --> 00:14:43.199
planned obsolescence either way i promise neither of them will ever happen

00:14:41.120 --> 00:14:48.639
with our merch from lttstore.com get yours today the next tier of anti-right

00:14:45.360 --> 00:14:51.360
to repair behavior is soft obstruction

00:14:48.639 --> 00:14:56.240
this is almost always on purpose and exists solely to prevent end users and

00:14:54.079 --> 00:15:00.480
third parties from repairing or rejuvenating their devices with

00:14:57.839 --> 00:15:04.720
manufacturers often citing safety as a justification

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that is what we ran into with well would have run into with our red pack and

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appears to be what we ran into with our other pack

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but how are they doing that well there are

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four different types of bms dumb basic

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smart and evil dumb is no bms at all like these rc lipo

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batteries each cell's voltage is maintained at the time of recharging by

00:15:26.079 --> 00:15:32.800
a much more sophisticated battery charger using the balance lead

00:15:29.839 --> 00:15:36.800
a basic bms allows you to safely use and charge the battery pack with a simple

00:15:34.560 --> 00:15:41.440
charger while protecting against under and over current situations so a lot

00:15:39.120 --> 00:15:45.680
better than nothing a smart bms will include cell balancing and some level of

00:15:43.759 --> 00:15:50.399
capacity learning along with self resetting for faults and

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ideally the ability to resell no not like this on facebook marketplace

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to replace the cells like we attempted

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today finally there's evil bmss which

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thankfully we don't see that much of these days what makes them evil is that

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after a set number of charge cycles they will switch off permanently even if they

00:16:08.079 --> 00:16:13.680
could still work and if you as a manufacturer ever built this sort of

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intentional e-waste shame on you all of which raises some questions then

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what exactly did we see today

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according to tyler from thtbattery.com red batteries at least these older red

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bricks are extremely challenging to resell because there's a good chance the

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bms will simply not wake up after the operation he hasn't put the r d into

00:16:33.199 --> 00:16:38.480
solving the problem because there just haven't been enough requests but there

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are a couple possible explanations for this the malicious one is that red's

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contract manufacturer could be using software to detect either cell

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disconnection or a change in capacity that will shut down the bms on purpose

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in which case it's basically an evil one for all

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intents and purposes the good news is that replacing the bms

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with a generic one for about 17 could get you back up and running if you don't

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need the original indicator lights or anything like that

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the careless possibility is that they used volatile storage for the bms's

00:17:10.559 --> 00:17:17.919
programming that wipes itself if it loses power given the cost difference

00:17:15.199 --> 00:17:21.600
this honestly could also be considered a malicious design decision

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now something that i want to make clear at this stage is that i am not advocating for user serviceable battery

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packs considering the precision required for safe assembly and the volatility of

00:17:29.760 --> 00:17:36.320
the chemistry that's just not realistic as we observed today

00:17:34.400 --> 00:17:40.720
but there's a middle ground here ah yes this pack is made by a company

00:17:38.880 --> 00:17:44.160
called bebop a german battery manufacturer that just so happens to

00:17:42.400 --> 00:17:48.880
supply one of the largest cinema camera makers in the world ari they advertise

00:17:46.960 --> 00:17:52.720
their cells to be replaceable and they even have an indicator that tells you

00:17:50.480 --> 00:17:56.480
when you've reached 80 and 60 percent of the original capacity when that happens

00:17:55.120 --> 00:18:00.400
you can send it to them and they will replace the cells at a discount other

00:17:58.880 --> 00:18:04.720
cinema brands take notes we're not even asking you to

00:18:02.640 --> 00:18:09.520
be as awesome as bebop but the least you can do is not put up roadblocks on

00:18:06.799 --> 00:18:12.559
purpose so then the safest way that you can help right now is just returning

00:18:11.280 --> 00:18:17.280
your batteries to be recycled when you're done with them but in an increasingly electrified world producers

00:18:15.760 --> 00:18:21.679
of battery-powered devices have a responsibility to plan ahead and to

00:18:19.520 --> 00:18:25.679
extend the lifespan of their products and figure out what's supposed to happen

00:18:23.919 --> 00:18:29.919
to them when they reach the end of their life on that note as it turns out one of the

00:18:28.240 --> 00:18:34.320
largest battery recycling facilities in north america retrieve technologies is

00:18:32.080 --> 00:18:37.919
just a few hours away from us so let us know in the comments if you want us to

00:18:35.679 --> 00:18:42.960
go check out how it's done in person and get subscribed so you don't miss it and

00:18:40.080 --> 00:18:47.039
don't miss our sponsor ifixit ifixit wants to help you keep your new devices

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LTT if you guys enjoyed this video maybe you'll enjoy our other this should be

00:19:12.240 --> 00:19:19.200
illegal video where manufacturers were caught swapping components on ssds

00:19:16.640 --> 00:19:22.559
effectively advertising one thing and delivering another