Cordless drill conversion to wall power

Someone mentioned somewhere about converting a cordless battery drill to corded operation. Can't find that thread, so, I'll just post up what I've come up with so they can see. (As they asked if I'd keep them updated).

I found an old 10 amp battery charger at an estate sale for $5. I then found two Makita 9.6v drills for $5 each at a thrift store. Between the two I was about to put together enough working parts for one useable drill. After modifying an IEC computer cord, this is what I came up with. Total investment costs: $32

The old charger has selenium diodes, so the actual DC output is around 11-11.2 volts. The 9.6 volt Makita drill motor should handle that without too much overheating. (We'll have to see). Anyway, the charger has an amp meter on the front, so I can keep an eye on the current during use. But that old heavy duty transformer should be able to handle the drills needs. I really only want this thing to do sheet metal screws and save wear on my corded drills.

The only modification I did to the drill was shorten the handle, as deleting the long stick battery meant that the super long handle was unnecessary. The modded drill almost looks like the short 7.2 volt Makita model. Will be nice in tight areas. And the 12 foot cord should give me plenty of length to plop the power unit down in one place and still be able to reach all around a rooftop air conditioner and its ductwork.

Here's what dremeling, epoxy, and some paint can make.

Someone has asked why go through all this trouble when you could just go out and buy a corded drill that uses the wall socket?
Good question!

First, I like doing things differently. When someone says so-and-so can't be done, I like trying to do it. Many people have said a workable converter - with enough amperage to run the drill - couldn't be made economically. One can if they scrounge and keep alert.
Second, I had a 6092DW drill for years, and loved it. I only stopped using it because the batteries just starting sucking. I would have done this conversion years ago if I'd known more about electricity then.
Third, I saved these two Makita's from oblivion at a thrift store. Knowing what I know now, I decided a conversion would be a worthwhile, yet challenging, project. I like saving useable tools, especially stuff people have thrown out.
Finally, if this jig works out, I will probably attempt to downsize the power unit with more modern components and a smaller/lighter case. If I can make that work - and the cost is not prohibitive - just think of all the discarded/obsoleted cordless drills that could be put back in service?

Bonneyman, awesome work! This looks really professional!

I love recycling older tools and bringing new life to them. You've saved those old drills! - Paul

I see no problem with this, those 9.6 Makita drills were FINE units, one of the few older cordless tools that it's actually worth buying new batteries for. The torque they could put out with a good pack could snap your wrist....

Question:

Did you convert a battery shell to have a tail or hard wire to the drill itself?

It you tailed a battery shell you could use it in all the equipment that uses that battery style. The old stuff is available for pennies on the dollar . . .

Interesting idea - nice work.

What's with all the haters? Some projects people build/work on/take pride in aren't my cup of tea but I can respect the work they do and the interest they take.

Cheers

Jim

Jim_No_Garage said:

Question:

Did you convert a battery shell to have a tail or hard wire to the drill itself?

It you tailed a battery shell you could use it in all the equipment that uses that battery style. The old stuff is available for pennies on the dollar . . .

Interesting idea - nice work.

What's with all the haters? Some projects people build/work on/take pride in aren't my cup of tea but I can respect the work they do and the interest they take.

Cheers

Jim

Click to expand...

Appreciate the compliments, guys!

I have two drills. This one I hardwired to the trigger terminals. The other I am thinking about gutting and modifying a dead battery and make an "adapter" out of it.