➜ Custom Battery Packs
CUSTOM BATTERY PACKS IN
Spot welding, not soldering, is the standard for lithium cells because heat damages them. Battery Power builds custom battery packs that way in , and across Lake County, matching your voltage, cell layout, connector, and casing. Tool packs, robotics, and mobility devices all fit. Licensed and insured, in-house builds, load tested before pickup, free evaluation through our contact page.
OFF THE SHELF DOES NOT FIT EVERY DEVICE.
Somewhere in your garage sits a tool that still works perfectly alongside a battery nobody sells anymore. That gap is exactly where we live. We open the housing, identify the cell chemistry and the internal configuration, then rebuild the pack around fresh matched cells so the tool goes straight back to work.
A rebuild also lets us improve what the factory shipped. Higher capacity cells, better protection circuitry, and cleaner internal connections all fit inside the original casing you already own.
- Fresh, capacity matched cells in every build
- Spot welded internal connections, never twisted wire
- Protection circuitry and fusing on lithium packs
- Load tested and documented before you pick it up
➜ CUSTOM BATTERY PACKS
BRING US THE OLD PACK AND THE SPECS.
Most builds start with something you carry through the door: a dead pack, a wiring photo, or a nameplate with a voltage and an amp-hour rating. From there we work out cell count, series and parallel arrangement, discharge load, and charging behavior. Medical devices, exit lighting, portable power stations, and legacy tool platforms all pass across our bench, and each one leaves with a build sheet describing exactly what went inside it.
LAKE COUNTY WORKSHOPS KEEP OLD TOOLS RUNNING.
Contractors, hobby machinists, and marina crews around Leesburg tend to hold onto equipment far longer than the manufacturers support it. Humid FL storage does the cells no favors either, and a pack left flat through a wet summer rarely recovers. Rebuilding beats replacing a whole platform, which is why so much of our custom work comes from people who simply refuse to scrap a good machine.
NOTHING INSIDE A BATTERY PACK IS NEW TO US.
Nickel cadmium, nickel metal hydride, lithium ion, and lithium iron phosphate each behave differently under load, and each punishes a different kind of shortcut. Across years we have taken apart enough failed packs to know where cheap builds go wrong: mismatched cells, soldered tabs that cooked the chemistry, and no balance circuit. We build the opposite way, then prove it on a load tester. What is powering the tool you cannot replace?
WHAT A PROPERLY BUILT PACK DELIVERS
EXACT FIT, EVERY TIME
Your device latches and seats the way it did when it was new, because the pack keeps the original dimensions, terminal position and mounting points instead of being wedged into place with tape and hope.
LONGER RUN BETWEEN CHARGES
Fresh cells chosen for capacity rather than price stretch the working time you get from a single charge, so a full shift or a full project no longer depends on swapping packs halfway through.
NO MORE DISCONTINUED DEAD ENDS
Equipment outlives its battery support all the time. A rebuild frees you from hunting auction listings for a part number that stopped shipping years ago, and keeps a perfectly good machine in service.
SAFER DAILY OPERATION
Balanced cells, correct fusing and proper insulation keep heat and voltage inside safe limits. That matters most on lithium chemistries, where an unmanaged pack is the thing that turns a small fault into a large one.
LESS WASTE, SMALLER SPEND
Rebuilding one pack costs far less than replacing an entire tool platform, and it keeps a sealed block of recoverable metal out of the landfill. Old cells leave with us for proper recycling.
A LOCAL BENCH, NOT A SHIPPING LABEL
Questions get answered by the person who built the pack. You can walk in, describe the problem, and see the work rather than mailing your battery away and waiting on a tracking number.
➜ WHAT WE BUILD
OUR CUSTOM PACK WORK
Six build types cover almost everything that reaches our bench, from a cordless drill that predates lithium to a solar bank feeding an off-grid cabin. Bring the application and the constraints, and we will scope the rest.
TOOL PACKS
Cordless Tool Packs
Drills, impact drivers, saws and vacuums running nickel cadmium, nickel metal hydride or lithium cells get rebuilt inside their original housings. The trigger, the charger and the tool footing all stay exactly as the platform intended them to be.
REBUILDS
Ni-Cd Drill Pack Rebuilds
Nickel cadmium packs suffer badly from partial charging and long storage. We strip the spent cells, fit high-quality equivalents, restore balance and refit the original casing and connector so a shelf full of matching tools stays useful.
LITHIUM SWAPS
Lithium Pack Conversions
Moving a legacy pack to lithium cuts weight and adds runtime, but only with the right management board and a compatible charger. We size the cells, integrate protection and confirm the host equipment tolerates the new voltage curve.
MOBILITY
Mobility And Medical Packs
Scooters, powered wheelchairs and transport devices need packs that fit sealed trays and hold capacity through daily cycling. Builds follow the original specification closely, with documentation covering charging limits and safe handling for the user.
PROTOTYPES
Prototype And Industrial Packs
Robotics builds, sensor arrays, drones and one-off machines rarely match a catalog part. We work from your voltage, current draw and physical envelope, then supply a tested pack with wiring and connectors ready to drop straight in.
OFF GRID
Solar And Off-Grid Builds
Cabins, trailers and portable power systems need banks sized to real daily consumption rather than a guess. We calculate usable capacity, wire the series and parallel arrangement correctly, and set the charge parameters to suit the chemistry.
★★★★★
Excellent Service and Support
Exemplary service! Amicable, punctual, overall went well.
Chris K.
➜ THE WORD ON OUR WORK
WHAT OUR Customers SAY.
Most custom work reaches our bench by word of mouth, sent over by a neighbor, a contractor or a repair shop that ran out of options entirely. Reviews across our listings tell the same story people tell us over the counter every week.
➜ Common Questions
FREQUENTLY ASKED QUESTIONS.
These are the questions people ask before they hand over a dead pack. If yours is not covered here, describe the device and the voltage through our contact page and we will answer it directly.
What does it mean to rebuild a power tool battery?
Rebuilding replaces the spent cells inside the pack while keeping the original casing, connector and electronics. The tool sees the same battery it always had, only with fresh capacity and clean internal connections carrying the current again.
Should I rebuild my old drill pack or just buy a new drill?
Rebuild when the tool itself is sound and you own several batteries or chargers on that platform. Replacing the whole system makes sense only when the motor, gearbox or switch is already failing alongside the battery.
Can I replace nickel cadmium cells with lithium?
Often yes, though it is not a straight swap. Lithium needs a protection board and a charger that follows a different voltage profile, so the conversion has to include both before the pack is safe to use.
Is a battery management system required in a custom pack?
For any lithium build, treat it as mandatory. The board balances cells, blocks over charging and cuts off deep discharge, which are the three failures that shorten pack life or create real safety problems inside a sealed housing.
Is spot welding better than soldering for lithium cells?
Yes. Spot welding transfers current in milliseconds and leaves the cell barely warm, while a soldering iron holds heat against the terminal long enough to damage the chemistry. Every lithium pack Battery Power assembles in Leesburg, FL, is welded.
Can different battery brands be mixed inside one pack?
No. Cells should share brand, capacity, age and internal resistance, because the weakest one sets the limit for the whole pack and gets pushed hardest during every cycle until it fails early.
What information do you need to design a custom pack?
Bring the old battery if you have it, along with the voltage, amp-hour rating, connector type and the space the pack must occupy. Knowing the equipment and how long it runs each day helps us size it properly.
Why bring a custom build to you rather than order one online?
Because an online listing cannot measure your tray, test your device or explain what went inside. Battery Power builds and load tests every pack here in Leesburg, FL, and stands behind work our own hands assembled.
➜ HOW WE WORK
FROM A DEAD PACK TO A TESTED BUILD, HERE IS HOW.
STEP 01
Bring In The Pack Or The Specifications
Walk in with the old battery, a photo of the label, or the numbers from the equipment manual. We confirm voltage, capacity, connector style and physical dimensions, then talk through how hard the device works during a normal day.
STEP 02
Open And Diagnose The Original
The housing comes apart on the bench so we can read cell type, count and wiring layout. Testing the old cells tells us whether the pack simply aged out or whether something in the equipment was overworking it.
STEP 03
Specify Cells And Protection
We select the chemistry and cell grade that suits your load, map the series and parallel arrangement, and choose the management board, fusing and thermal protection. You get the plan and a written figure before anything is assembled.
STEP 04
Build And Weld The Assembly
Cells are matched, spot welded into modules, insulated and wired to the protection circuitry. Everything gets sleeved, secured against vibration and fitted back into the original casing with the correct connector and cable routing.
STEP 05
Test Under Real Load
The finished pack goes on a tester for voltage, capacity, cell balance and behavior under discharge. We only release a build once the numbers match the specification we quoted and the pack charges cleanly end to end.
STEP 06
Fit, Explain And Support
You collect the pack with a build sheet covering chemistry, capacity and charging guidance. If the device needs the battery fitted or the charger checked for compatibility, we handle that here before you leave.
➜ GET YOUR FREE EVALUATION
BRING US THE PACK EVERYONE ELSE GAVE UP ON, AND THE EVALUATION IS FREE.
Bring the battery, the equipment or just the numbers off the label. We will tell you honestly whether a rebuild makes sense, what it will hold afterward and how long it takes. Start it through our contact page.
WHAT YOUR EVALUATION COVERS:
- Cell chemistry, count and configuration identified
- Capacity and internal resistance tested on the old pack
- Honest rebuild or replace recommendation
- Written build plan with cells and protection listed
- Charger compatibility checked against the new pack
- Free recycling of the cells we take out
