Spectacular failure #5632

[eastern57]

http://i306.photobucket.com/albums/nn260/eastern57/Misc/fail.jpg

This is what's left of a 4.8v NiMh 4AA rechargeable battery pack that was ruptured - it got so hot it melted through the coverings; provided, it was heat shrink wrap, but this is an excellent example of what NOT to do.

What happened? - I was planning on documenting my process of refitting my MHS with my new CF v4.. and in my excitement (and over-confidence), I lost track of what I was doing... I tried to stuff too much into my hilt, pressed too hard, applied too much torsion, heard a "pop", "hisss" and then smoke.

- 4.8v 4AA pack w/clip - now severed (above)
- CF v4
- 4x 3mm accent LEDs
- recharge port
- P4 LED
- pvc tube for sled
- 2x long shaft tactile switches

http://i306.photobucket.com/albums/nn260/eastern57/Misc/wiring.jpg
http://i306.photobucket.com/albums/nn260/eastern57/Misc/wiring2.jpg


How did this happen? Simple - I didn't follow my own advice: TOO MANY WIRES cluttered everything up... I somehow thought I could squeeze all the above into a ribbed section and 5" double female - and in theory, it IS possible - but I didn't plan properly, I didn't measure my space, I just saw a gap and thought "sure, it'll fit". Obviously, it didn't.

So now I offer my mistakes to everyone. I am an avid practicer of the trial and error method of learning. But it is ultimately useless to the masses unless I share...

lesson learned...

[Strydur]

Been there..done that

[Stevegel]

Been there..done that

Also,did you get a free t-shirt?:)

[xwingband]

Been there..done that

Ditto.

Wire management is a pain in the arse. I'm not perfect, but I've vastly improved in just a year. Half the battle is using the right stuff. Get thin stranded wire! Use the right heatshrink!

I redid one of my sabers that had a V2 and it was nuts how much I saved by putting new thinner wire.

Tip#32412
Have two wires that go together? Like the power, speakers, switches, etc... they're going to the same place. So heatshrink them together! It makes identifying them a lot easier and it halves your chances of a random wire getting in the way.
Ex. I know the set coming out the bottom of my board would be speaker and power usually. So the set that's red and black easily identifies the power.

[eastern57]

back on the horse... we'll see how it goes.

edit: got it working, but had to swap out a bunch of wires that had melted. accent LED work nice. CF is working fine...go figure... absolutely amazes me how tough that thing is.