On Mon, 16 Aug 2010 18:43:08 +0100, "john hamilton"
wrote:

Sigh. No imagination left on Usenet. OK, no soldering or heat
allowed. Some ideas.

http://tinypic.com/r/iqx3pf/4

Plan A: Looks like the rivets used to mount the contacts have a
through hole in them. Shove a 2-56 flat head bolt through the hole
from the inside. Put two washers, lockwasher, and a nut on the
outside. Wrap the wire around the bolt between the washers and
tighten the nut. If you can't find a bolt that fits, you might be
able to find a suitable copper rivet. Beat on it with a hammer to
assemble.

Plan B: Thread the rivet hole and insert a lockwasher and 2 washer
sandwitch held in place with a small bolt. Getting the bolt length
correct will be the major challenge.

Plan C: Strip off about 3cm of wire from the leads. Bend into a
spiral. Shove the spiral between the battery contacts and the
matching rivet and spring. Be sure you have a good electrical
connection. Wrap the whole mess in giant shrink tube, electrical
tape, duct tape, or just bury it in hot melt glue. Whatever it takes
to keep the wires from moving.

Plan D: Buy a dual AAA cordless phone battery pack. They usually
have two leads and a connector. Chop off the connector, strip the
leads, and twist the matching wires together. Wrap with electrical
tape or use shrink tube.

Plan E: Brute force cold welding. If the wires are copper, you can
just run them through the holes in the terminals and pound everything
flat with a small hammer and anvil. The copper will cold flow and
eventually create a solid connection. You may need to add additional
soft copper wire filler to get a proper connection. See any jewelry
maker or blacksmith for details.

Plan F: Forget the holder and just spot weld wires directly to the
battery. This is far more fun than learning to solder as it throws
spark and hot slag all over the place.
http://www.youtube.com/watch?v=yabesdeGKJo
Since you probably don't have a cazapitive discharge spot welder, drag
it down to the local Batteries Plus store and have them do it.



--
Jeff Liebermann
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558