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original |
my repro |
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Although a modern version of the above battery is still available, if you can find
a source, they are quite expensive. Eveready has just
discontinued production of their EN6 which has been a long time
replacement for the original No. 6, 1.5 volt dry cell used in
many 1920's radios.
I'm going to show you how to make an
original looking battery so you can make your vintage radio that
requires a No. 6 "A" cell look and operate as it did originally.
Now refer to the pictures below (enlarge by
clicking on them) and follow these steps:
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Start with a 2.5" paper mailing tube. I use
the 13" size that can be cut to make 2 batteries. -
image #1 (below)
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Cut the tube in to 2 6" lengths being
careful to make true and even cuts. - image #2
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Trim the lip from one of the mailing
tube ends. - image #3
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Punch or drill holes for the hardware,
install 5/8 brass 8/32 bolts, thumb nuts and wire. -
image #4
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Apply a bead of Elmer's glue as
shown in - image #5
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Trim & remove excess glue. -
image #6
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Carefully push the prepared tube end (with
hardware & wires mounted up into the glue bead leaving 3/16"
space evenly above the top of the plastic tube end. -
image #7
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Let the glue dry for about 30 - 40 minutes.
Make sure the top is perfectly level and fill the end cap with
*epoxy tinted to the desired color all the way to the
paper brim. Note; the Elmer's glue will not adhere to the
plastic end cap, the glue is to seal it to the paper so the
epoxy will not leak through - image #8
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I use Tap Plastic's Super Hard
4- 1 epoxy. I'm sure other brands and resins will work equally as well.
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Prepare a 2.5" mailing tube
as described above for the housing.
The images below can be enlarged by clicking on them
#1 mailing tube |
#2 cut in to 6" lengths |
#3 trim off lip |
#4 install terminals |
#5 bead of Elmer's |
#6 smooth out seal |
#7 ready for epoxy |
#8 poor in epoxy |
Now stuff it with batteries
and apply the label.
The images below can be enlarged by clicking on them
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The epoxy will require 24 or more hours to
completely cure, then continue with these steps:
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Prepare 6 "C" cells as shown in -
image #9 (below)
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Solder all 6 negative ends together with a
common black wire as shown in - image #10
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Solder all positive poles together on each
end and connect an orange or red wire to each end with a 6" lead
out wire. - image #11
(be sure and take care not to
allow any shorts to occur, there's a lot of available current in
6 of these batteries in parallel). Dress
the two wire so they both come out one end.
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The battery tube & battery pack now ready.
- image #12
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Cut a thick cardboard insulating ring (this
is to prevent the underside of the battery terminals brass
hardware or wiring lugs from coming in contact with the battery
pack end. - image #13
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Wrap the battery pack with some thin
packing material or paper so it fits snugly inside the tube and
shove it along with the insulating cardboard ring all the way in
to the tube. - image #14
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Now connect the two wires from the battery
pack to the wires coming from the battery terminals that connect
to the top of the battery tube. - image #15
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Now put the other end cap in place and you
are ready for your label - image #16
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Apply the label and your battery is ready
to use - image #17
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#9 prepare "C" cells |
#10 solder negative ends |
#11 wire all in parallel |
#12 tube & "C" cells |
#13 prepare to stuff |
#14 ready to stuff |
#15 stuffed & wired |
#16 ready for label |
#17 apply label |
Now you can order a
complete battery label set as seen for the
Radiola IV. The "A" & "C"
labels are self adhesive. The "B" label is not (it's heavy paper and
is to be glued in place.
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| made to fit a container with 3 "AA" cells, 2"(w with
rounded sides) x 5/8"(d) x 2.5" (h)
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I have more reprint labels not yet posted or
pictured,
if interested,
inquire.
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