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RadiolaGuy.com |
 FRESH,
NEW No. 6 retro batteries now available
I'm always seeking new labels to add to my inventory, those who send me a label I don't have or high quality scan that I can re-master will receive up to three re-mastered labels free including postage. > View some examples some labels that I am seeking.
PAPER MEDIA OPTION, the labels
are normally printed on peel & stick (self adhesive backed paper). Some
have requested the labels printed on heavier non-adhesive backed paper. If you
desire the non-adhesive backed heavier paper (you must apply the
*appropriate glue), place a simple note in the "Desired Label" box along
with your label choice.
========================================
2 "B" battery labels + "C" cell label
(as shown below), 5 piece set
========================================
I'm going to show you how I 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.
FOR MORE DETAILED
IMAGES, GO TO MY WEB SITE:
http://www.radiolaguy.com/info/No6_A_cell.htm
There, you can enlarge all
the small images shown below.
DISCLAIMER!
PLEASE NOTE THAT THE AUTHOR ASSUMES NO RESPONSIBILITY FOR
PROBLEMS, ERRORS OR FAILURES THAT MAY OCCUR IN ANY ATTEMPT
FOLLOWING THE SUGGESTIONS I HAVE OUTLINED BELOW. THESE ARE ONLY
SUGGESTIONS AND SOME DETAILS MAY HAVE BEEN BE LEFT
OUT OR LEFT UP TO THE BUILDER TO FIGURE
OUT.
Option 1 -
order a
Modern No. 6 battery and re-label it with one or more of my
labels.
Option 2 (instructions
below):
Refer to the steps and pictures below
(enlarge images by
clicking on them) and follow these suggestions:
Start with a 2.5" paper mailing tube. I use
the 13" size that can be cut to make 2 batteries. -
image #1 (below)
Cut the tube in to 2, 6-1/8" lengths being
careful to make true and even cuts. - image #2
Trim the lip from one of the mailing
tube ends. - image #3
Punch or drill holes for the hardware,
install 5/8 brass 8/32 bolts, thumb nuts and wire. Be
sure the terminals are flat against the plastic end cap so they
do not interfere with the batteries to be installed later.
Put a piece of electrical tape over exposed terminal area to
prevent contact with the batteries that will be installed later. -
image #4
Apply a bead of Elmer's glue as
shown in - image #5
Trim & remove excess glue. -
image #6
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
Let the glue dry for about 30 - 40 minutes.
Before pouring the epoxy,
carefully apply a coating of Vaseline or wax to the top threaded
area of the brass posts (this is to prevent the epoxy from
migrating up the threads of the posts). Do not allow any of the
wax or Vaseline to get any on the areas that will be submerged
in the epoxy. 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
*I use
Tap Plastic's Super Hard
4- 1 epoxy and their pigments. I'm sure other brands and resins will work equally as well.
Prepare a 2.5" mailing tube
as described above for the housing. Now stuff it with batteries
and apply the label.
The epoxy will require 24 or more hours to
completely cure, then continue with these steps (below):
Prepare 2 dual "C" holders (available from
Radio Shack) as shown in. -
image #9
Rewire each holder so when the batteries
are installed as shown, they will be 4 batteries in parallel. - image #10
Insulate all the exposed wire and outside
contact areas (all areas are not shown), be sure and do all
on each end of both holders). -
image 11
It is very
important that you make sure you have wired the holders
correctly so all 4 batteries are in parallel and installed as
shown, wire the holders so the center (top of No. 6 terminal) is
positive.
- image #12
The batteries and holders are now
ready to stuff in the tube. If you sized everything correctly, the
the batteries and holders should fit snugly in the tube with the
end cap in place.
I suggest trimming off the excess label
with a very sharp razor knife after the label is secured in
place and then placing the end cap on. - image #13
Your battery is ready
to use - image #14
I strongly recommend that
you use only high quality, brand new, fresh batteries such as
Duracell or Energizers. Since the batteries are all in parallel,
one weaker battery will drain power from the others and
discharge more quickly. Another way to put this is there will be
current flow from the strong batteries to the weak one/s having
a battery charging effect. ========================================
click ^ to enlarge
Unfortunately, a replacement battery for
this historical set has long since been extinct but all is not
lost. Here I will detail how I fabricated a working battery for
my Safari. It will be much easier if you have an original
battery so you can gut it out and replace the contents with new
rechargeable NiCad's.
If you do not have an original, you will
need to fabricate a housing the same size as the original
battery. The measurements are; 7 1/8" tall x 2 5/8" wide x 1
1/2" thick, rounded on all 4 sides. the hardest part will be
finding (or fabricating) an appropriate socket.
If you are not
resourceful, don't have good technical skills & don't know
how to solder properly, you just as well
stop here and seek some help from a skilled technical person. A minor
modification is also required inside the Philco Safari. This
will be explained below.
If you have an original battery, first
remove the paper cover. If done carefully, it can be reused, if
it's badly damaged, I can supply a
repro.
Now refer to the pictures below (enlarge by
clicking on them) and follow these steps:
Find an original battery or fabricate a
similar container for the new NiCad's. ref #1
Cut the old container in half and gut the
contents being careful not to damage the socket. ref #2
Once the old battery can is cleaned out,
prepare 7 (sub C size NiCad's). Wire them in series, attach the
positive and negative lead wires, bind them together and
insulate all the terminals. I enclosed the whole NiCad package
in a large piece of heat shrink tubing. ref #3
Now stuff the new battery package in the
bottom half of the can and solder the wires to the battery plug
socket (top of the can). I used thick cardboard spacing
pieces on all 4
sides and the bottom of the battery pack. ref #4
Place a piece of insulating material on the
top of the battery pack to prevent any shorts across the battery
socket's underside and slide the top of the can over the top of the battery
pack.
Once everything is properly fitted and
aligned, tape
the two halves together using a single layer of metal, aluminum duct tape
carefully placed without bulges or wrinkles. Use this type
because it's thin, has great adhesive power and if done
carefully it will not leave a noticeable seam. ref #5
Before Appling the new label, be sure and
test your new battery pack for function and proper polarity.
Now you can now apply either you original label or I can provide a
reproduction
label for a nominal fee.
IMPORTANT, before powering up your Safari with your new
battery, a small modification must be made inside the TV. The
old battery provided 7.5 volts, the new one will give 8.4 volts.
A resistor value change should be done to reduce the voltage to
the CRT and the rest of the set.
See Schematic & Mod.
If your Safari works properly from house
current, you are now ready to charge the new battery. With your
TV set to the charging mode, charge the battery for 24 hours. If
your TV is not working properly, have it fixed by someone
knowledgeable before attempting to operate or charge the
battery.
With these smaller size (sub-C cells), my
set will run about 2.5 hours before noticing any decrease in
performance. It takes 20 - 24 hours to recharge the battery pack
using the original built-in charger.
NOTE - the set must be turned on and the rear switch in
the charging position to charge the battery. Be sure and turn it
off after 24 hours. There is no built in protection from
overcharge or charge monitoring system in this set. The images below can be enlarged by clicking on them A new
wrap around label is available, go
here
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