Electronics

Hands-on electronics projects: DIY battery packs from salvaged lithium-ion cells, and the small radio and sensor builds around my homelab.

Not everything in my lab runs in a virtual machine. Some of it has a soldering iron involved. This is where the hardware projects go: things I design and build myself, what I learned along the way, and what I’d do differently.

What also might creep in are electronics repairs, fixes, and builds not related to my home lab or computer systems.

What you’ll find here:

  • DIY battery packs: designing a standard pack I can reuse for different projects, and salvaging, testing and sorting 18650 cells from old laptop batteries to build it.
  • Safety first: lithium-ion cells store a lot of energy, so every build comes with the checks and precautions I actually use.
  • Small builds around the homelab: radios, sensors and other gadgets that don’t fit anywhere else.

The DIY battery pack series picks up where the 2021 design post left off, starting with harvesting the cells in March 2027.

Designing a DIY Battery pack

DIY battery pack · Part 1

Designing a DIY Battery pack

by Jan Holbo Rasmussen

Many people have built battery packs out of both Nickel and Lithium based batteries for their own personal use. Maybe as a battery bank for a Solar system or for a smaller use case. I have been contemplating to build my own version of a standardised(ish) DIY battery pack. One that I could use for multiple applications.

I will be using 18650 Lithium-Ion batteries mostly harvested from disused laptop battery packs. If you have access to laptop batteries in chances are that you would be able to salvage at least some of their cells for this use. The challenge for the future in this respect will be the ever thinner laptops are using more custom battery cells than 18650 cells in order to become as thin as possible. Another source could be surplus battery packs for discontinued laptops and other battery operated appliances. These would then be available for purchase at sell-out prices.

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