xbox 360 controller 18650 battery holder

thingiverse

A remix of Kingnai's battery holder https://www.thingiverse.com/thing:110764 to use 18650 batteries on xbox 360 wireless controller. IMPORTANT NOTES 1) voltage will be a little higher than regular batteries since a charged cell is over 4v instead of 3.2v for two AA batteries. This didn't give me any problem aside the fact that the ring led stays dimly lit even with the controller off, but I've only tested this on one controller so your results may vary and I'm not responsible for you burning off your controller because you're too lazy to read this. You can use a diode to drop down the voltage by 0.6v and it will just be a bit above a regular battery pack. 2)Many 18650 cells don't come with built in protection circuit. This means if you leave it in the controller you will drain it too much and ruin it (or have it explode or start a fire I don't know I'm not a battery doctor). Again, I don't take any responsibility for you burning down your house or dying. You can solve this by adding a protection board, just like the diode you can fit everything inside since the battery pack is actually empty inside, or just don't leave the battery in the controller and charge it every now and then. Printing 0.25mm layer height, whatever infill you want but use 1mm walls and top/bottom for extra resistance and drilling capability. No need for supports or brims or raft. Assembly You'll need 4x M3x10 or M3x16 countersunk screws and 2x M3 nuts, or the closest imperial equivalent. Holes are 2.5mm and an m3 will tap into it cutting the threads, so you don't need nuts to keep them in place, the nuts are to hold the wires attached to the contact screws. To make the springs you can use steel wire (I'm using 0.6mm stainless steel wire), coil it around an M8 bolt or similar, leaving a little lead to "solder" the copper wire on. You can't actually solder to steel but you can coil the copper wire around the steel wire and add some solder and it will lock in place and make good contact. Once this is done, slide the springs inside the slots of the 18650 holder and add some hot glue to keep them in place. Slide the wires inside a hole (you might need to drill it out if your wires are big) and connect them to the contacts using the nuts. Do not mess up the polarity. Once this is done just hot glue the bottom shell to the top shell and you're good to go. You can keep the battery in with a piece of wire between the two holes at the top, and you can just loosen it a bit to slide the battery out. There are many holes on the top shell, so you can use whatever battery holder you want, keep in mind that the three ones in the center are 2.5mm ready to be tapped with an M3 screw.