Gigapan Epic Pro Battery Pack
The pack is glued together so carefully pry it apart.
I wasn't careful enough because I cracked the socket.
The cracked socket.
Lift the whole assembly out of the case. Note the other half of the cracked socket is still in the plastic case.
The detail of the socket and wiring. I think the yellow part is a thermistor which shuts off the current if the batteries get too hot.
The back end of the battery assembly.
How the batteries are soldered together.
Sub C 6000mAh NI-mh Batteries with tabs for about 2 bucks each on ebay.
Take the old batteries apart. I used a razor blade to slit the shrink wrap off. Snip the tabs with a scissors and remove the black round insulators.
Snip off the end of the tabs so they don't stick out when you solder the batteries together.
Tin the tabs with solder and place the black insulating washers on the positive side of the batteries.
The batteries must be in series with positive soldered to negative. Push the pre tinned tabs together and melt them with the soldering gun. Build 2 rows of 3 batteries.
Carefully solder the thermistor to the positive battery tab.
Tape the 2 sets of 3 cells together with electrical tape.
Line up the front socket so it will fit in the plastic case. Place the assembly in the plastic case so the socket lines up with the opening. Bend the tabs and rotate the batteries so it all fits. Solder the remaining tab on the plug to the tab on the battery.
Put the insulator back between the socket and the batteries. At this point solder the positive and negative tabs together at the back of the 2 rows of batteries. You will now have 7.5v at the socket. If your socket was broken like mine make sure that the center post in the socket isn't touching the ground or you will get a direct short.
I wrapped some tape around the battery pack to hold the top insulator on.
You can see how the center post and the ground in the socket were touching where the strip of cardboard is. Once the batteries were put back in the case and the socket was aligned with the other half there was no problem.
I just put the 2 halves of the case together without any tape or glue and pushed it into the Epic Pro. You could probably glue the case together but there is no room to wrap it with tape.
I turned it on and it fired right up.
I hooked it to the charger and it came right up. The charger light was red. In about 30 minutes it turned green letting me know that the pack was fully charged.