DeWalt 20V MAX 5Ah Battery Rebuild | Step-by-Step Tutorial

Rebuilding a DeWalt 20V MAX 5Ah lithium-ion battery pack with brand new cells. In this video, I take you through the full rebuild process — from opening the case, removing old cells, spot welding new ones, and reassembling the pack. ⚡ What you’ll see in this video: • Safe teardown of the OEM battery case • Preparing and installing new 18650 cells (I used different cells in this build, but you can use Samsung 25R – available here): https://renewspark.com/products/samsung-25r-18650-3-6v-2500mah-li-ion-battery-cell-flat-top • Spot welding nickel strips – Nickel Strips: https://renewspark.com/products/precut-nickel-strips-dewalt-20v-max-5ah-battery-pack https://renewspark.com/products/pure-nickel-strips-0-2x10x100mm-50pcs-precut-battery-pack-spot-welding • Spot welder: https://amzn.to/4neVzzh • Fish-paper insulator rings: https://renewspark.com/products/18650-adhesive-insulator-rings-550pcs-battery-cell-insulation-pads • Final test of the rebuilt battery – Battery Tester: https://amzn.to/4mVhw6c 🔧 Tools used in this build: Soldering station: https://amzn.to/4ghKhIA Solder wire: https://amzn.to/3HL5jm3 Desoldering tool: https://amzn.to/46oi3s1 Desoldering wick: https://amzn.to/4gceNn3 Cut-resistant gloves: https://amzn.to/4nVFSgL 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/renewspark-tools/id6755784193 If you’re interested in seeing any other rebuilds, let me know in the comments so I can make a video for it 🔋 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. 👉 Subscribe for more rebuilds: https://www.youtube.com/@RenewSparkBatteries?sub_confirmation=1