The nicads have been leaving a coating of KOH all over everything and really needed better ventilation. The holes for the fans were already there, but the vents were very small for this type of flooded battery pack. So I clamped the lid to the mill and CNC’d nice round 2 inch holes for the exit vents.

Here is the exit vent for the nicad pack. It uses a 3 inch plastic cap anchored with 4 screws and nyloc nuts to 2 inch plastic pipe adapters, sealed to the battery box lid with silicone.

Here is the exit vent for the nicad pack. It uses a 3 inch plastic cap anchored with 4 screws and nyloc nuts to 2 inch plastic pipe adapters, sealed to the battery box lid with silicone

This is the cover for the 80mm fans and the inlets on the Nicad pack. These covers are just simple sandwich boxes from Target. The fans were also sealed to the battery box lid with silicone.

This is the cover for the 80mm fans and the inlets on the Nicad pack. These covers are just simple sandwich boxes from Target. The fans were also sealed to the battery box lid with silicone.