This part bolts in place of the factory battery holder on 12v PowerWheels and allows you to slide in 1 or 2 DeWalt batteries (1.5/2.0/3.0 Ah sizes). With a few .250 QC connectors and some wire, you have a PowerWheels that runs 4mph on the slow speed or at a good jogging speed on the fast speed!
I printed this with 3 walls and a .8mm nozzle in PLA at 200-210C on a 70C bed. Rotate the part so the flat base is down.
Soldered terminals and bare copper
I salvaged some .250 blades off of a standard automotive relay to use as the battery contacts and some 12 gauge solid copper for the connections. You can use crimp on .250 QCs and insulated wire too, they just need to project out the slots about 1/4 inch.
Connections inserted into the cavities
The cavity and connections cross since the batteries are rotated 180 degrees relative to each other and thus the + and - terminals are as well. The 2 level cavity allows bare copper to be used without much risk of shorting. I added a bit of hot glue to keep the contacts from pushing out when you insert a battery.
- First I created a part to represent the DeWalt 1.5Ah battery I had. Then I created 2 more parts referencing the first to represent the material needed to hook into the battery latch and grooves and the second to represent the cavity that needed to remain to clear the battery/terminals/etc. I found dimensions of the larger DeWalt batteries and added a reference plane so I could account for larger batteries being used.
- Then I created a part to represent the battery space in the PowerWheels vehicle, including the mounting screw locations.
- I created an assembly with 2 instances of the battery holder along with the PowerWheels battery space part and positioned the batteries to clear everything and provide easy insertion/removal access.
- I created the final part shown above that connects the mounting locations and battery holders, adding cavities for the conductors along with ribs and fillets to add strength where needed.