Replacing Cells in Power Tool Battery Packs

By Mike attempts | Dec 06, 2025
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After rebalancing the cells in two old Milwaukee M18 battery packs, one is already down to 3 bars after the first recharge while the other won't hold a charge at all. I figured this would be a good opportunity to compare soldering against spot welding when rebuilding the packs with new Samsung lithium-ion cells. This procedure for replacing the lithium-ion cells in power tool battery packs will work for Dewalt, Makita, or any other brand. See links below for the parts and tools I used:


Spot Welder:

https://amzn.to/4oDG84c (affiliate*)


Flush Cutters:

https://amzn.to/4oENtQO (affiliate*)


Weller Soldering Station:

https://amzn.to/4a0SiAu (affiliate*)


Weller 5 Tip Set:

https://amzn.to/3Kv9EuU (affiliate*)


Bass Sponge Tip Cleaner:

https://amzn.to/3MknL6O (affiliate*)


Liquid Solder Flux:

https://amzn.to/4pSJ6CT (affiliate*)


Lead-Free Solder:

https://amzn.to/4rYagdx (affiliate*)


Aluminum Soldering Clips:

https://amzn.to/48yZtNJ (affiliate*)


Battery Charger:

https://amzn.to/47bQpOl (affiliate*)


Security Bit Set:

https://amzn.to/48wcKIH (affiliate*)


Slim Multi-Bit Screwdriver:

https://amzn.to/42K6c5u (affiliate*)


*Purchasing from these Amazon affiliate links earns my channel a small commission. Think of it as a tip that doesn't cost you anything. Thanks for the support!