I had a classic Black & Decker Dust Buster vacuum in my shop for years as they are great for cleaning up table top debris and sanding dust while working on r/c gliders.
About 2 years ago, the vac's RPMs would start to fall quickly after a few seconds even after a full charge. I suspected a failing battery pack, and put this now useless unit in storage even though it had only a few total running hours on it.
I was putting together the shop space in my new house and found the old Buster in a box with other workshop junk. I love to recycle old machines so I poured myself a cold Porter and started to disassemble the unit to check out that old failing battery pack. The Buster says 14.4 volts on the side so I was already thinking of putting in a 4S Lithium Ion or Lipo pack that would match that rated voltage.
The included photos show the internals and the wiring changes I made.
The Buster comes apart easily, (warranty voided!) and I found a huge plastic battery box inside with a 12S 1500mah NiCD pack inside. I knew that some of the cells might be bad, and tested the voltage of each, looking for any reading under 1.1v. Two cells were at 1v, and another was at 1.1v. The rest of the pack was at 1.2v, though I suspected some memory effects had reduced the packs capacity. Total weight of the pack was 19 oz.- 538 grams!
For a replacement battery I picked a 40C rated Thunder Power 4S 2200 Lipo which was no longer flight worthy, but still fine for low amp draw applications. You could use a 4S Li-on or Li-Fe pack for this application/hack as well. This battery had the old TP style balance connector on it and the wires were very short, so I just plugged the balance connector into a spare TP to JST-XH adapter board which I could then plug into any of my Lipo chargers. Total battery weight was now just 10 oz. - 283 grams!
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