Dewalt Battery Adapter for TS100 Soldering Iron

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.

Post-Printing

1. Assembly is fairly straight forward. Attach the blade connectors to your length of wire. Insert the blade connectors into the holes, make sure the blades slide into the battery, and then secure them in place with 5-minute epoxy, or hot glue. I would recommend the epoxy, as it will give you a bit of time to install the strain-relief piece before it hardens.
2. Solder the XT60 connector to the wire ends, making sure to check your polarity before soldering.
3. Assemble the swing arm and bearing holder, and then attach to the main body.
4. Insert the brass sponge into the semi-sphere.

How I Designed This

Designed using Fusion 360, starting with maglub's f3d, and then adding the spade connectors, as well as the soldering iron holder.

I've attached my f3d file, in case you need to change any of the dimensions.