Build your own A123 flight packs
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Get one of these packs.
I got mine off Amazon.
  Futaba style leads,
heavy duty.
  Balance leads - from
radicalrc.com
  You need a Torx bit with
a hole to undo these screws.

My aircraft flight packs had aged so much that their capacities were below safe levels. I did some research about newer battery technologies and decided to switch to using A123 cells for my flight packs. Here I demonstrate how I did mine.

Be careful when working with these packs as the energy in the cells are substantial. Any conductive material near these cells are dangerous. It is important to note that the polarity of these cells are different to NiCd and other cells. Observe the polarities as printed on the sheaths of the cells. Use of a volt meter is recommended. Proper care will prevent your charger from smoking.

The balance leads used here are for the Thunder AC6 charger. Other chargers may use different plug types or pin-outs.

             
 
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Unscrewed and opened up.   Pack removed from base
enclosure.
  Remove from covers. The
wires are still attached.
  Wires have been snipped.
             
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Pairs of cells. I used a sharp
pair of snips to cut the strips.
  Another view of the cells.   Thin CA used to fuse the
pair of cells.
  Tinned tabs. Use rosin core,
not acid.
             
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Balance lead and power
leads are soldered on.
  Leads are soldered on and
packs are ready to be skinned.
  Heat shrink. Also from
radicalrc.com
  Completed packs.
             
 
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