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Things You'll Need
Instructions
Preparation
Place the six battery cells, soldering iron, solder, emory cloth, sponge and assembly kit on a non-conductive work surface, such as a wooden table.
Plug in the soldering iron into a suitable wall outlet. Refer to the instructions supplied with the soldering iron with regard to setting the proper temperature and general operation.
Clean the metal "+" positive and "-" negative ends of each cell with an emory cloth. The cleaning process will rid the cell contacts of impurities and allow for better connections.
Wipe off the soldering iron tip with the moist sponge. Do not allow the soldering iron tip to make contact with the sponge longer than one or two seconds at a time, as extreme heat will damage the sponge.
Apply fresh solder to the tip of the soldering iron and repeat the wiping process until the tip has a solid, shiny surface.
Assembly Process
Open the stick pack assembly kit and remove the small rectangular-shaped battery bars.
Secure the first three battery cells, side-by-side, in a staggered "-,+,-", fashion, between two small pieces of wood, banded together with two rubber bands. Set the banded cells on the work surface with the staggered "-,+,-" cell orientation facing up.
Place the tip of the soldering iron on the first "-" cell contact and apply a small blob of solder; spread the solder to make a 3/16-inch round solid circle. Do not heat the cell contact for longer than two seconds, as damage to the cell can occur. Repeat the solder application to the second "+" cell.
Hold a battery bar on top of the first "-" and second "+" cell contacts, using a pair of forceps. Heat the battery bar over the first cell to melt solder and fuse the battery bar to the contact. Solder the remaining end of the battery bar to the second cell.
Turn over the jig and solder a battery bar from the second "-" cell to the third "+" cell, using the same methods outlined in the previous steps. Remove the first three cells from the jig and bind the last three cells in a "+,-,+" configuration.
Solder battery bars to the first "+" and second "-" battery cells. Turn over the jig and solder a battery bar to the second "+" and third "-" battery cells. Remove the cells from the jig. Carefully straighten each set of three cells by carefully folding the battery bars; each battery bar should fold over on itself, allowing each set of battery cells to form a straight line.
Place both sets of cells side-by-side and solder a battery bar from the end of one set to the other set of cells. Feed the black "negative" and red "positive" connector wires from the assembly kit through the top protective cap, also included with the kit.
Solder the connector wires to the corresponding "+" and "-" cell contacts, located at the opposite end of where you joined the two sets of cells with the battery bar.
Fit the bottom protective cap to the battery-bar side of the pack. Slide the top protective cap over the opposite end of the cell pack. Place the heat shrink tube supplied with the assembly pack evenly over the battery pack.
Heat the heat shrink tubing with a hair dryer or heat gun, until the heat shrink contracts sufficiently to secure the cells and protective caps to finish the process.