Rechargeable screwdriver converted to alkaline batteries

[bonneyman]

An oldtimer came into the store wanting to know if we could replace his unresponsive rechargeable batteries in his B&D screwdriver. A co-worker tried to take the thing apart before calling me. When I looked at the thing I informed the customer I didn't think it was meant to be disassembled and the cells replaced - they just want you to buy another driver. He said the thing was 5 years old, and he'd just buy another one. As he was purchasing the new one I asked if he was just going to trash the old one. he said yes. So I asked if I could have it - maybe I could turn it into something useful? He said fine.

I took it home and figured I could mod it to use AA alkaline batteries. Took some dremeling and removal of internal gusseting but was able to get 2 pairs of AA cells to fit inside and the thing works fine. One has to take it apart to swap out the cells instead of plugging it in (the downside). But the swap out procedure takes about 5 minutes, compared to probably an hour on the wall.

Not a big project like you other guys do but I was happy with it and my co-workers were fist pumping me over it.

Here's the drill with the front gear case removed.

 

[bonneyman]

Here's the unit split into two halves, with the battery packs crammed in the handle. No modification was necessary on the orange half, though some material had to be removed form the black half. The space between the motor and battery packs - where the direction switch resides - is pretty busy. But she works.
It originally had two 1.2VDC batteries - motor says it's a 2.4V. Now it has four 1.5VDC cells Two pairs in series and those then put in parallel. The DC motor should easily handle the 3V total, and I should get twice the running life as the OEM. We'll see!

And the only external hint of any changes is the lack of the male wall plug in the back and an ABS cover installed.