Cell holder

A cost-effective way of making simple cell units to use with 4mm leads[?], follows.

Equipment Required (to Make 60 cell Holders)

• 60 pieces of wood at least 120mm x 36mm and 20mm thick
• 'D' cell plastic holder (available from most Design & Technology suppliers)
• 4mm terminals, 60 black and 60 red (available from most electrical component retailers)
• small screws to fit through the base of the cell holders
• Extra flexible lead wire, black and red
• Solder + soldering iron
• Pliers
• Screwdriver
• Drills 7.5mm, 5mm & 3mm
• Countersink drill bit
• Solder Flux

Method for making the cell holders

1. Get the wood cut the wood to the correct size and sanded if need be.
2. Drill 2 x 7.5mm holes at either end as show in fig 1.
   

1. Drill 2 x 5 mm holes near those.
2. Counter sink the larger holes to about half way, so that you can attach the nut of the 4mm terminals.
3. Insert the 4mm terminals in the larger holes, one of each colour in either end, and secure with nut.
4. Attach the plastic cell holder with the 2 screws (diagonally opposite), first drilling holes, and making sure that the end with the spring goes near the black terminal.
5. Cut a 5cm piece of each wire, strip the ends and solder onto the tags on the plastic cell holder, making sure you do not take to long or the tags will melt off. Ensure you have got red wire to the red terminal and black wire going to the black terminal. Then push the wire through the 5mm hole and out the other side so you can then solder it onto the 4mm terminal.
6. It should look something like this. see fig 2. these are usually very durable and can be used in conjuction with bulb holders etc.