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DeWalt 20V MAX Battery Rebuild – Step-by-Step Upgrade from 6Ah to 9.8Ah

RenewSparkBatteries

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DeWalt 20V MAX Battery Rebuild | From 6Ah to 9.8Ah Upgrade

In this video, I show you how to rebuild and upgrade a DeWalt 20V MAX 6Ah power-tool battery step-by-step — from safely removing the old cells to spot-welding, balancing, testing, and final charging.

What you’ll learn:
• Safely disassembling your DeWalt 20V MAX battery pack
• Removing old nickel strips and cells
• Installing new 21700 cells with insulation rings
• Spot-welding new pure nickel plates
• Balancing and testing internal resistance (IR)
• Verifying charge and final voltage

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🔋 Cells (available from RenewSpark)

Molicel P50B 21700 – 5000mAh, 60A continuous:
https://renewspark.com/products/molic...

See all 21700 cells:
https://renewspark.com/collections/21...

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🔧 Parts & Materials

Nickel strips (10 mm × 0.2 mm):
https://renewspark.com/products/0-2mm...

Kapton tape:
https://renewspark.com/products/polyi...

Fish-paper insulation rings:
https://renewspark.com/products/21700...

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⚡ Tools Used

Spot welder: https://amzn.to/4neVzzh
Soldering station: https://amzn.to/4ghKhIA
Internal resistance tester (YR1035+): https://amzn.to/3JQG9Tw

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⚡ All rebuild parts and supplies available at https://renewspark.com?utm_source=you...

Rebuild complete – upgraded from 6Ah to 9.8Ah.

Tools I Use (Free App):
🔧 Build safer, cleaner battery packs with the RenewSpark Tools app — IR checker, pack designer, wire & nickel sizing, load calculator, and more.
📱 Download on the App Store:
https://apps.apple.com/us/app/renewsp...

Subscribe for more rebuild tutorials and DIY battery upgrades.

🔋 Disclaimer: Lithium-ion battery rebuilding can be dangerous if done incorrectly. This video is for educational purposes only. Attempt at your own risk and always follow proper safety precautions.

12 Comments

@daverussell9875 5 months ago

That’s a very good video and we appreciate you putting all the tools and parts in there. Very interesting. Thank you.

@vutran-ds1gw 4 months ago

great video man, thanks 👍

@duotronic6451 4 months ago (edited)

Removing the spot welded tin strips: Pinch tin strip ends with needle nose, then roll back over welds so tin rolls up on the round needle nose. Rips welds apart gentle and clean. ❤❤❤

@AlexBeljo 8 months ago

7:18 на корпусе выдавленно маркирова + и -

@PapaBearPenney 2 months ago

Take a small drill bit and weaken the spot welds a little bit, they will break off easier.

@gazbullen 8 months ago (edited)

nice but should really of remade the fuse on neg side like the original had the nikle strip has a 1/3 of it cutout to act as a fuse incase of a short to save a fire

@chrisharvie-smith486 8 months ago

Start the same way: Use a thin tool to get the free end of the nickel stip up enough to grip with needle nose pliers.
The change: Rotate the pliers so the nickel rolls around the tip & lets you pry safely against the battery with Just the rolling.

> Don't go back & forth as this will metal fatigue the strips you want intact. <

It might rip the old cells a little but no crushing or puncturing between the + & - plates. Put the old cells into a ceramic pot / pyrex bowl & recycle.
That ripping is how you know you've bonded correctly with a spot welder ! (with a spare / sacraficial / old similar cell.)

Hope that helps. 🙂

@RollinYZ 3 months ago

Can anyone rebuild mine for me?

@George_Shonia 8 months ago

i FOUND out that there is even P60B with 6ah capacity, so it will be even bigger capacity, that is just crazy oportunity for genuine business right there.. just make bunch of this, add 100$ for selling price, would be sold like a hot cacke

@douglashunt5342 10 months ago

Im a bit confused, I have a dewalt pak that has 18650's im it, I was unaware that dewalt used the 21700 cels in these paks.

@-AirMan- 6 months ago

Good video but that music is terrible bro....

@dolrr54 7 months ago (edited)

4.8 amp hour lbatteries are too low of draw for power tools service and will be damaged when used in high demand tools. This is also NOT a safe practice.You also eliminated the fuseable link strip which makes that battery unsafe too.