Black & Decker PS130 Modular Charging Station & Li-Ion Adapter

A modular DIY system for upgrading the classic Black & Decker PS130 battery from Ni-Cd to Li-Ion and building a dedicated charging station.

The project reuses the original battery housing and mechanical interface while replacing the outdated Ni-Cd cells with modern 18650 or 21700 Li-Ion cells and a suitable BMS.

The second part of the project is a custom modular charging dock with spring-loaded contacts and an integrated 12.6 V CC/CV charger.

🔋 Project Idea

The original Ni-Cd battery had reached the end of its useful life, and the original charger was no longer available.

Instead of trying to restore the obsolete Ni-Cd system, I decided to modernize the entire power system while keeping the original battery housing and its mechanical connection to the tool.

The project consists of three main parts:

• Li-Ion battery conversion — replacing the original Ni-Cd cells with Li-Ion cells and a 3S BMS.

• Internal adapter/insert — a 3D-printed replacement for the original cell assembly that organizes the new wiring and contacts.

• Modular charging station — a dedicated dock with spring contacts and a 12.6 V CC/CV charger.

The result is an old power tool with a completely modernized battery and charging system.

🔌 Compatibility

The primary target is the Black & Decker PS130 battery housing.

The design is also intended for compatible housings sold under:

• PS130

• PS130A

• A9252

• A9275

Compatible aftermarket replacement housings may also work if they have the same mechanical dimensions and contact arrangement.

Important

Compatibility is determined by the physical geometry, not only by the model number or voltage.

The following must match:

• battery housing dimensions;

• docking geometry;

• contact position;

• upper battery interface;

• mechanical locking/locating features.

Other Black & Decker 12 V batteries should not automatically be considered compatible.

🛠 Modular Charging Station

The charging station is based on a Black and Decker PS130 Battery Wall Mount design published on Printables.

The original holder was extensively modified and expanded into a complete modular charging dock.

Original PS130 Battery Wall Mount on Printables

The modular construction makes it possible to print and replace individual components instead of rebuilding the entire station.

The design also leaves room for further modifications of the charging electronics.

⚡ Spring Contact System

The dock uses custom-designed spring contacts made from 8 mm nickel-plated metal strip.

The strip is bent to the required shape and installed into dedicated slots in the printed contact holder.

This provides:

• reliable electrical contact;

• spring-loaded pressure against the battery terminals;

• compensation for small mechanical tolerances;

• replaceable contact material;

• a simple and inexpensive contact solution.

🔋 Li-Ion Conversion

The original PS130 battery housing is reused.

The internal Ni-Cd cell assembly is replaced with a Li-Ion pack using:

• 18650 cells, or

• 21700 cells.

The project is designed around a 3S Li-Ion configuration:

• nominal voltage: 11.1 V

• maximum charging voltage: 12.6 V

• BMS: 3S Li-Ion

• charger: 12.6 V CC/CV

The actual capacity depends on the selected cells and parallel configuration.

For example, a 3S2P configuration uses six cells arranged as three series groups with two cells in parallel in each group.

🧩 Internal Printed Adapter

The NiCa-Cell insert replaces the original internal Ni-Cd assembly.

It provides:

• mechanical support for the new battery assembly;

• positioning of the new conductors;

• electrical insulation;

• contact positioning;

• internal mechanical alignment;

• adaptation of the original housing to the new Li-Ion configuration.

The external battery housing and its original interface with the power tool remain unchanged.

🔌 Charging Station Electronics

The dock is designed to accommodate:

• 12.6 V CC/CV Li-Ion charger

• AC mains connector

• power switch

• internal wiring

• spring-loaded charging contacts

The charger must be specifically suitable for 3S Li-Ion batteries and provide a final charging voltage of 12.6 V.

Do not use the original Ni-Cd charger to charge the converted Li-Ion battery.

The BMS, charger, wiring and cell configuration must be selected according to the actual battery configuration and the current requirements of the tool.

🖨 Recommended Printing Settings

Recommended materials:

• PETG

• PETG-CF

• ABS

• ASA

For mechanically loaded parts and spring/contact components, a stronger and more temperature-resistant material is recommended.

Suggested settings:

• Infill: 20–30%

• Perimeters: 3–4+

• Increase the number of perimeters for structural and contact parts.

• Use supports where required by the selected print orientation.

Exact settings depend on the printer, nozzle size and material.

📦 Model Parts

Charging Station

PS130-BaseDown
Lower part of the charging station housing.

PS130-BaseUp
Upper part of the charging station housing.

Dock_AKB
Dock and contact assembly.

Connector_AKB
Battery contact adapter.

Battery Conversion

NiCa-Cell
Internal printed adapter replacing the original Ni-Cd cell assembly.

🧰 What This Project Does

Old Ni-Cd battery → Li-Ion 3S → BMS → original PS130 housing → modular charging dock

The goal is simple:

Keep the old tool. Replace the obsolete battery technology. Build the charger yourself.

⚠ Safety

This project involves Li-Ion batteries and mains-powered charging electronics.

Make sure that:

• the Li-Ion cells are suitable and properly matched;

• the BMS is designed for the selected 3S configuration;

• cell polarity is correct;

• the charger output is 12.6 V CC/CV;

• all high-current connections are properly insulated;

• the charger and BMS current ratings are appropriate for the application;

• the battery is mechanically secured inside the original housing.

Incorrect Li-Ion assembly or charging can result in fire, damage to equipment, or personal injury.