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Disassemble NEXTEC LED Work Light

A project log for Dustbuster Upgrade

An old Dustbuster gets a new lease on life when its worn 9.6V NiCad battery is replaced with a 11.1V Lithium Ion battery.

RogerRoger 12/25/2017 at 03:430 Comments

The next step is to disassemble the NEXTEC LED work light and see if we can use it to adapt the old Dustbuster to lithium-ion power.

The wish list of the disassembly operation are:

The things we don’t care about:

With these goals in mind we start with the obvious task of removing the four visible screws. After the screws were removed there was one more fastener: a small metal C-clip holding the two halves together near where the pinkie finger rests while holding the light. The clip was designed to require a specific tool for a clean removal. For people who are unconcerned about cosmetic damage, it could be persuaded to abandon its post with pliers.

Work Light Disassembled

Looking at the disassembled light, we see we can easily re-purpose the battery compartment and associated battery connector for the project. The third item on the wish list – the over-discharge protection circuit – is unfortunately incorporated onto the LED circuit board and not an easily separated part. We’ll just have to be careful when using the upgraded Dustbuster and not discharge it too much.

Having the battery compartment and electrical contacts is great. It bypasses a lot of iterative CAD work and 3D printing to pin down proper dimensions to fit the battery. The next step is to join the two devices together.

(Cross-posted to NewScrewdriver.com)

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