Convert Cordless Drill To Corded: A Complete DIY Guide
Cordless drills offer convenience and portability, but when batteries fail or lose capacity, you’re often left with an expensive paperweight. Instead of purchasing a new drill, converting your cordless drill to corded operation can save money and reduce waste. This conversion allows you to power your drill directly from a wall outlet, eliminating battery limitations while maintaining your tool’s functionality. Whether your batteries have died or you simply want unlimited runtime, this guide will walk you through the conversion process step by step.
What You’ll Need
Before starting the conversion process, gather these materials:
1. Your cordless drill with dead or removed battery
2. AC adapter with appropriate voltage rating (matching your drill’s battery voltage)
3. Wire cutters and strippers
4. Soldering iron and solder
5. Heat shrink tubing
6. Electrical tape
7. Multimeter (for testing)
8. Battery housing (optional – can reuse existing battery case)
9. Connector that fits your drill’s battery terminals
Understanding Your Drill’s Power Requirements
Determining Voltage Requirements
The first step is identifying your drill’s voltage requirements. Most cordless drills operate on 12V, 18V, or 20V batteries. Look at your existing battery pack or check the drill’s manual for this information. You’ll need an AC adapter that matches this voltage rating to ensure proper operation without damaging your drill.
Checking Current Requirements
Cordless drills typically require 2-5 amperes of current. To maintain proper torque and performance, select an AC adapter that can deliver sufficient current. A higher amperage rating is acceptable (the drill will only draw what it needs), but never use an adapter with lower amperage than required.
Method 1: Using the Battery Housing
This method maintains the original form factor of your drill by utilizing the existing battery housing.
Preparing the Battery Housing
1. Carefully disassemble the battery pack by removing screws or prying open the plastic casing.
2. Remove the battery cells, keeping track of how they were connected.
3. Clean the interior of the battery housing, removing any corrosion or debris.
4. Identify the positive and negative terminals that connect to the drill.
Connecting the AC Adapter
1. Cut the connector end from your AC adapter cable, leaving plenty of wire length.
2. Strip approximately 1/2 inch of insulation from the wire ends.
3. Using a multimeter, identify which wire is positive (usually red) and which is negative (usually black).
4. Solder the positive wire to the positive terminal in the battery housing.
5. Solder the negative wire to the negative terminal in the battery housing.
6. Apply heat shrink tubing to the soldered connections for insulation.
7. Drill a small hole in the battery housing for the adapter cable to exit.
8. Reassemble the battery housing with the new connections inside.
Method 2: Direct Connection Adapter
If you prefer not to modify your battery housing or it’s damaged beyond use, you can create a direct connection adapter.
Creating a Custom Connector
1. Study the connection points where the battery attaches to the drill.
2. Create or purchase a connector that matches these contact points.
3. Solder the positive wire from your AC adapter to the positive contact on your connector.
4. Solder the negative wire from your AC adapter to the negative contact.
5. Insulate all connections with heat shrink tubing or electrical tape.
6. Create a housing for your connector using plastic, wood, or 3D printing if available.
Testing and Securing the Connection
1. Before attaching to the drill, use a multimeter to verify correct voltage output from your adapter.
2. Connect your custom adapter to the drill.
3. Secure the adapter to prevent it from disconnecting during use.
4. Test the drill at low speed initially to ensure proper operation.
Improving Your Conversion
Adding Strain Relief
To prevent wire damage and ensure longevity:
1. Add a strain relief mechanism where the cable enters any housing.
2. Use cable ties or clamps to secure the cord to the drill body.
3. Consider adding a cable management system to keep the cord organized during use.
Voltage Regulation (Optional)
For optimal performance and protection:
1. Consider adding a voltage regulator if your AC adapter’s output isn’t precisely matched to your drill’s requirements.
2. Install a fuse in-line with the positive wire for added safety against power surges.
Safety Considerations
1. Never use an AC adapter with a higher voltage than your drill requires.
2. Ensure all electrical connections are properly insulated.
3. Don’t operate the converted drill in wet conditions.
4. If the drill overheats during use, disconnect immediately and check your connections.
5. Consider adding a ground wire if your drill originally had a three-prong battery connection.
Frequently Asked Questions
Will converting my cordless drill to corded affect its performance?
When done correctly with a properly rated power supply, your drill should maintain its original torque and speed capabilities. In some cases, performance may even improve with consistent power delivery compared to a weakening battery.
Can I convert any cordless drill to corded power?
Most cordless drills can be converted, but tools with sophisticated battery management systems or electronic controls may be more challenging. Simpler NiCd or NiMH battery-powered drills are typically easiest to convert.
Will this void my drill’s warranty?
Yes, modifying your drill in this way will almost certainly void any manufacturer warranty. Only proceed if your warranty has expired or you’re comfortable with this trade-off.
Can I still use batteries if I want to after this conversion?
If you use Method 1 and create a removable adapter that fits in the battery housing, you could potentially switch between corded and battery operation. However, most conversions are permanent.
How much money will this conversion save me?
Compared to purchasing a new corded drill ($50-$150) or replacement batteries ($30-$100 each), this conversion typically costs $15-$30 for the AC adapter and necessary components, representing significant savings.
Converting your cordless drill to corded operation gives new life to a tool that might otherwise be discarded, saving money while reducing electronic waste. With proper care in selecting the right power supply and making secure connections, your converted drill can provide years of reliable service without the limitations of battery power.