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by banu


A guide to making a casing to hold 2 batteries in series. It is a basic tool that will help us power many more tactivities based on electricity.

    • Scissors have functional sharp edges. Contact may result in injury. Always keep blades away from fingers and body. Handle with care.

    • Please realize that batteries might cause damages like leaking, fire or explode when misused or defective. Refrain from mechanically damaging them.

    • Be careful not to short the terminals of the batteries.

  1. Draw outline of the foam on a white sheet.
    • Draw outline of the foam on a white sheet.

    • Now mark vertically at 1.5 cm and 6.7 cm from top end of the line.

    • Horizontally, we mark at 0.7 cm ,2.2 cm ,3.9 cm and 5.4 cm respectively from the edge of the paper.

    • We draw lines from these markings to form rectangles from their intersections .( The hatched portions) and then cut out the outline of the foam formed on the paper.

    • Apply transparent tape to stick the cut out, rectangular paper on a foam piece temporarily.

    • Now cut two slots of 5.5 cm X 1.5 cm (the hatched portion ) on the foam & remove the cut pieces to create pockets for holding batteries.

    • Cut 7 copper strips from copper tape, each of length 7 cm, and 2 strips of 5 cm each.

    • The foam springs are made using 10 mm foam strips and copper strips as shown in the next step.

    • Take 2 of the 1 mm foam piece and fold it from the middle as shown.

    • Now take the 50 mm copper strip and wrap around the folded foam.

    • Cut out any protruding portion of the foam and the foam springs are ready.

    • The foam with slots made in 'step 1' is taken and 7 cm copper strip cutouts are wrapped around the shorter edge of the foam piece.

    • Now take another strip and connect two terminals on one side. Consider this to be side 2 (marked with red arrow) and other side as side 1.

    • Now take two wires of 15 cm each,strip off 4 cm and 1 cm insulation on either sides of each wire.

    • Now bind the 4 cm over the copper tape on side 1 of the foam.

    • Repeat the same for both of the terminals on side 1.

    • Now cover the winding with another copper tape.

    • Apply glue to the cardboard, and to the foam on the backside of the terminals where the wires are connected.

    • Now take the foam and paste it over the cardboard.

    • Now place the foam springs made in 'step 3' across the slots.

    • Your DIY battery holder is ready to be used.

    • Use LED to test the battery holder functionality . The orientation of the LED is important, the longer lead is the positive pin.

    • Here is a circuit diagram of the holder. We are connecting the batteries in series for at total of 3 volts.

    • If the battery holder refuses to light an led, check the contact between the pins and battery terminals.

    • Be careful not to short the terminals of the batteries. If the batteries heat up while in the holder, this could indicate an electrical short circuit. Remove the batteries and check your connections.

Suhail Ahanger

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