Dewalt Battery Adapter for TS100 Soldering Iron by BlaydeRunner

Last crawled date: 3 years, 1 month ago

This was heavily inspired by mightynozzle's TS100 Soldering Iron Holder Station, urw's Dewalt Battery Adapter, and maglub's DeWalt battery holder, so credit for their original designs go to them.
I recently purchased a TS100 soldering iron, but I wanted to be able to use it in areas away from power. Since I have Dewalt batteries available, I thought I'd combine a solder station and the battery adapter into a single unit.
This uses an XT60 connector to connect to the adapter that comes with the soldering iron.
For this, you'll need:
608 bearing, preferably 608ZZ so that it's all-metal, and less likely to melt for the iron's heat.
2 x bolts and 2 x nuts for the 2 joints. Since I used some random hardware I had lying around, I've supplied the Fusion 360 file so you can adjust the size of the bolt hole to your own hardware
1 x short wood screw, to attach the cable strain relief to the base
2 x blue blade connectors
length of appropriate-gauged wire
XT60 connector
Brass wire solder sponge
2-part epoxy (or hot glue gun)
IMPORTANT NOTE
Make sure to set your voltage cutoff properly on your TS100. Since there is no built-in battery protection with Dewalt batteries, there is a risk of draining your battery below safe levels.