Restoration Idea 18

Vintage No. 6 Dry Cell Comes to Life Again

Leclanche' is the technical name for (credit to the inventor Georges Leclanche' in 1866) the dry cell. These 1.5 V cells were a safer alternative to the wet cell (lead-acid) which were common as "A" battery or tube filament battery. Their shortcoming is that they are Primary Cells. This means they cannot be recharged like the wet cells. These cells had a carbon positive post, surrounded by a manganese dioxide paste (electrolyte) surrounding the post. Holding the paste was a metal can or the negative post. Eveready marketed the cell as the number 6. Four were needed hooked up in series to provide adequate filament voltage for the UX201 and similar battery tubes. According to Eveready specifications, if the load was 0.6A (1-2 UX201 tubes connected in series) and I ran the cells 2 hr/da, with a dropout voltage of 30% of total, the cell would last about 50 hours. Most radio sets had 3 to 5 UX201s so the life would be shorter so often these cells were wired in parallel for longer life. These cells became popular for education and industrial purposes because of the large current capacity. Improvements in primary and rechargeable (secondary) battery technology eventually made this cell obsolete.

I picked an exhausted vintage Montgomery Ward No. 6 cell cheap on Ebay. Sat on the shelf for years until I wanted to make it run again. The following is the resurrection of a vintage Montgomery Ward "Trail Blazer" No. 6 Dry Cell.

Taking It Apart:

Separate Battery Casing >>>>> Remove Seal >>>>>>>> Exposed +POST & Paste >>> Remove + Carbon Post >>>> Loosen Electrolyte Paste >>> Complete Disassembly

Rebuilding Process

To make the equivalent No. 6 current capacity, 2 size D cells in parallel would equal or exceed to original specs. Alkaline cells would make a super No. 6 cell in current capacity.

Repair the metal case with solder braid >>>> Wire D cell holders in parallel >>> Install new battery top and stiff wood base >>> Install D cells >>> Completed reusable No 6 Cell

BEFORE AFTER

What happens if the metal case is no good?

Got a Mallory No 6 IGNITER made around the 1960's. The metal case that holds the electrolyte is corroded and can't be saved.

1. I carefully removed the original label and the thumb screws used for the + and - terminals. Manage to save neg terminal bracket. Also I was able to save the bottom part.

2. . Cut a piece of 2" ABS sewer pipe to the length of the cell.

3. Install negative bracket to ABS pipe.

4. Rolled precut cardstock to get closer to the correct diameter (between 2.25 to 2.5 in dia). LOCTITE Hybrid Adhesive to glue cardstock to tube then use rubber bands to keep tight.

5. Install old label back on with LOCTITE hybrid glue and rubber band to allow adhesive to lock pieced together.

6. Use two single C cell holders wired in parallel and mount to aluminum or metal frame.

7. Made battery top cap out of aluminum and drill hole for positive terminal. Mount #10 machine screw equal in height of negative terminal. On reverse side added heavy gauge copper or brass bracket on other side of terminal.

8. Connect wires and lap solder batter holder positive lug to copper bracket.

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