retro/vintage remake of the classic battery cases

[tim.senecal]

Has anyone tried to make a 3d printed update of the classic 6N-1200sc 7.2v hump pack or the 5N-1200sc 6v pack?  if not, can someone give me the dimensions of either of those battery packs in their collection?  I think it would be a cool way to hide a 2000mah 2s lipo in a vintage car.

[bRIBEGuy]

I can try and get some measurements for you, or even whip up a quick 3d model.  Let me see if I have some free time tomorrow...

[tim.senecal]

bRIBEGuy,  measurements would be enough, and thanks...

[bRIBEGuy]

Here ya go!

[bRIBEGuy]

[bRIBEGuy]

The battery in the background is a 3S 2200mAh LiPo and it would fit inside with zero issues.

[Willy iine]

Very interested to buy if someone can upload it at Shapeways!   

I would run NiMH  Sub-C in my case.. in the case.   

 

[bRIBEGuy]

How would you all envision the case halves going together?  Click in with tabs?  A few screws?

[Juggular]

I took it apart once.  I don't think there was any room for screws nor click tabs.  The upper and lower halves were glued.  The case did have a very shallow glue-tab all along the case. 

But the case was so narrow, it didn't have enough room for my clunky solder.  The case could only take spot welded cells, or a very skillful soldering job.    

Fortunately, there are $50 spot welders. (I've never used it, so I don't know how good below item is.) 

https://www.amazon.com/Portable-Machine-Welding-Equipment-Storage/dp/B092DB5R3S/ref=asc_df_B092DB5R3S/?tag=hyprod-20&linkCode=df0&hvadid=507714472492&hvpos=&hvnetw=g&hvrand=4999691609444248893&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9007234&hvtargid=pla-1325880395164&psc=1

 

 

[Willy iine]

3 hours ago, bRIBEGuy said:

How would you all envision the case halves going together?  Click in with tabs?  A few screws?

I would just plastic cement them together.  

[WillyChang]

7 hours ago, Willy iine said:

 

I would run NiMH  Sub-C in my case.. in the case.   

 

NiMH subC are a slightly bit taller than ole Sanyo 1200mah Nicads though

Even when we build a “naked” niMH hump pack with battery bars & shrinkwrap it barely fits in the 5c trays. 

[tim.senecal]

It would have to be glued together for those that wanted to use nimh or nicd cells like the original...  but for those of us wanting to use lipos, the corners could have sleeves for screws.  I do see that someone on ebay has replacement decals/stickers for both the 6n and 5n packs.   There is no reason not to make two versions of both the 6n and 5n packs,  one set for true purists, and one set for those just looking to replicate the look.

sub-c NIMH cells that are 23mm x 43mm can be found.

that leaves 2mm or so in the width (per side) (including space for welded bars), but only 1mm in height (per side)..  i guess the top and bottom walls of the sub-c packs will need to be thinner, or the replicas will have to be taller than the originals.

the real difficulty is going to be replicating the embossed "TAMIYA Ni-Cd BATTERY" text for the authentic look i am sure the purists will want.

[Willy iine]

@tim.senecal Indeed, I can make the SubC’s fit if the housing is the same size and thickness as the original. 

I too would like the Tamiya deboss in the housing if possible..!   I mean if it’s just the hump back housing without the deboss, I can make the housing out of styrene and it won’t be that difficult to do..

[nicherotors]

Here is a design @Jamesssb made earlier.  Happy to share files if helpful. 
 

From Shapeways there aren’t many combinations of appropriate material and colour choices to choose from for this project - closest I think will be PA12 in gray.

https://www.shapeways.com/materials/multi-jet-fusion-pa12

In PA12 I doubt the debossed text will be that sharp.  Suspect versatile plastic would be a bit sharper but then you’ve really only got white or black as practical colours to choose from.  Fine detail plastic would certainly give you the precision but would be too brittle in my opinion and would need painting. 
 

These two shells have been designed to be glued together to save space on the inside.

Was reluctant to put Ni-Cd on the outside if actually a lipo was hidden inside for fear of someone else later down the line incorrectly charging it.

A couple of strange things you only notice when measuring things - the chrome sticker isn’t round (and neither is its recess) and the chamfered top and bottom isn’t at 45 degrees but again I question whether this will be noticeable once printed.

I think a commercial hump pack (with the leads on the correct side - we’ve seen them on both sides from the same manufacturer) with the heat shrink removed would fit but this is currently untested. Although, given this thread I’m minded to get a set printed to find out. 

[SuperChamp82]

Shapeways’ materials leave a coarse finish even if you choose their ludicrously expensive / top of the range polymer

So this would likely end up a costly ‘labour of love’ to look anywhere close to the original if using them ?

A number of people here produce way better bespoke results with their own printing kit - but (again) it’s time consuming for them and relatively expensive vs restoring the shell of vintage pack + adding Lipo if that’s the goal ?

I’d also bond the restored battery case using rubber not plastic cement - maybe Shoo Goo ? - so you can slice it open more easily to replace the cells ?

Interesting project regardless 👍

[Willy iine]

@SuperChamp82 Hummm.. some of the high resolution prints I’ve bought from Shapeways in the semi-clear ikky color is quite smooth..  There is no need to sand beyond what I would normally sand hard shells..

Maybe I just got lucky.. (?) 

For example @nicherotors brand side mirrors.   The finish is super smooth with simple Tamiya primer and paint.. I did barely any sanding.. #1000 very gently..

[bRIBEGuy]

The other option, albeit more expensive, would be to have them CNC machined out of plastic...

[SupraChrgd82]

There's a 5-cell file for printing: 

 

"tamiya battery box" 3D Models to Print - yeggi - page 11

 

 

[tim.senecal]

8 hours ago, SupraChrgd82 said:

There's a 5-cell file for printing: 

 

"tamiya battery box" 3D Models to Print - yeggi - page 11

 

 

The 5 cell battery box yeggi link goes to a thingiverse 404 page...  but there is also a yeggi 6 cell link that does go to a valid thingiverse "thing"...   https://www.thingiverse.com/thing:2131193

[SuperChamp82]

11 hours ago, Willy iine said:

@SuperChamp82 Hummm.. some of the high resolution prints I’ve bought from Shapeways in the semi-clear ikky color is quite smooth..  There is no need to sand beyond what I would normally sand hard shells..

Maybe I just got lucky.. (?) 

For example @nicherotors brand side mirrors.   The finish is super smooth with simple Tamiya primer and paint.. I did barely any sanding.. #1000 very gently..

@Willy iine - small and simple always works with effort sir 👍

Conversely, I’ll trade you man hours sanding down a Shapeways 1/12 934 wheel set ? 😂

Less angular than the battery box but took weeks to get any where near factory finish !

And the Shapeways’ cost of printing something as big as a battery case in fine polymers still makes me ponder 🤔

[Willy iine]

36 minutes ago, SuperChamp82 said:

@Willy iine - small and simple always works with effort sir 👍

Conversely, I’ll trade you man hours sanding down a Shapeways 1/12 934 wheel set ? 😂

Less angular than the battery box but took weeks to get any where near factory finish !

And the Shapeways’ cost of printing something as big as a battery case in fine polymers still makes me ponder 🤔

Yeah, those wheels take a lot of time to sand!!  

I too wonder about the cost..yikes. 

[JeffSpicoli]

These come up on eBay from time to time but being NICD, I bet they are deader than a doornail even if NOS.

[IceBox]

A case I cut open . Going to glue it together empty for a display. I’ll lend it out,,  it if helps ,, 

 

 

[JeffSpicoli]

Anyone have one of these melt partially as a kid? LOL I had one that was partially melted but still worked.  

[Willy iine]

@IceBox Is there a reason why you removed the cells if only for display?   I have a few of those hump backs and they still have cells in them... and holy cow they still held a charge!   

I too display them.. with time appropriate cars.