DeWalt 20V MAX 5Ah Battery Rebuild | Step-by-Step Tutorial

Rebuilding a DeWalt 20V MAX 5Ah lithium-ion battery pack with brand new cells.

In this video, I take you through the full rebuild process — from opening the case, removing old cells, spot welding new ones, and reassembling the pack.

⚡ What you’ll see in this video:
• Safe teardown of the OEM battery case
• Preparing and installing new 18650 cells (I used different cells in this build, but you can use Samsung 25R – available here):

https://renewspark.com/products/samsu...

• Spot welding nickel strips – Nickel Strips:

https://renewspark.com/products/precu...

https://renewspark.com/products/pure-...

• Spot welder:
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• Fish-paper insulator rings:

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• Final test of the rebuilt battery – Battery Tester:
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🔧 Tools used in this build:
Soldering station: https://amzn.to/4ghKhIA

Solder wire: https://amzn.to/3HL5jm3

Desoldering tool: https://amzn.to/46oi3s1

Desoldering wick: https://amzn.to/4gceNn3

Cut-resistant gloves: https://amzn.to/4nVFSgL

Tools I Use (Free App):
🔧 Build safer, cleaner battery packs with the RenewSpark Tools app — IR checker, pack designer, wire & nickel sizing, load calculator, and more.
📱 Download on the App Store:
https://apps.apple.com/us/app/renewsp...

If you’re interested in seeing any other rebuilds, let me know in the comments so I can make a video for it

🔋 Disclaimer: Lithium-ion battery rebuilding can be dangerous if done incorrectly. This video is for educational purposes only. Attempt at your own risk and always follow proper safety precautions.

👉 Subscribe for more rebuilds:    / @renewsparkbatteries