1. Prepare the internal components:
- Positive current collector, positive briquette, positive separator
paper, separator basket,
negative separator paper, negative briquette, negative current
2. Prepare the case: Sand the outer outer face edges flat and smooth
with a big piece of sandpaper on a flat surface, file or cut out sags
in the 3D printed
slots, drill out filler hole to 1/4", put in 5/16" ball bearing and
a little methylene chloride around it so the lip of the hole
conforms/melts to shape of the ball (trim thin scrap created in hole if
3. Cut & prepare the top side sheet plastic piece.
(70 x 100mm + 20 x 20 mm negode tab.)
4. Slip the 'flexible graphite' positive current collector tab under
slots and position it in the 65x65x4.0mm lower box.
5. Fill the top slot with heat glue so the terminal won't leak. Get
some in behind too, with a thin knife or something. (work fast on
that.) (This step may optionally be done after assembly is complete. If
you break the graphite now getting some glue under it, it's easy to
pull it out and start over.) Also heat-glue the top end of the inner
slot to prevent escape of electrode material through the tab slot into
the upper chamber. (must be done now.)
5b. Optional: surface treatment of graphite current collector to
conductivity: acetaldehyde doped with osmium. (More on this later.)
6. Place the posode briquette in the lower box on top of the current
7. Place a piece of 69x69mm watercolor paper on top of the briquette.
7b. Before 7, fold a little piece of paper with a 3mm edge. Place it
over the briquette and fit the fold pointing down between the briquette
and the upper wall. This should help keep briquette material from
escaping from under the flat paper into the upper chamber.
8. Place the separator basket on top of the paper. Press the edges down
and glue it in (3 edges) with methylene chloride. Let it harden.
9. Drop 5 to 10cc of toluene (methyl benzene) with a dropper at various
the basket/paper/briquette/graphite to absorb in and dissolve graphite
powder. The graphite will
form more conductive random lamilae and nanotubes to improve
conductivity as the toluene evaporates and it solidifies again. (around
40% more conductivity) Give it some hours to evaporate. (until it
doesn't stink of toluene.)
10. Place a 64x70mm piece of watercolor paper into the basket, folding
it up the side of the basket at the top and bottom (where there are no
lips at the edges).
11. Place the negode briquette in the top basket, on the paper.
12. Place the zinc current collector on top of the basket with its
terminal extension sticking out the 'minus' slot.
13. Run a bead of methylene chloride
around the outside edge of the case and put
the top face on the cell. (Avert your nose. Wetting the fingers
with it seems okay but it's not good stuff to breathe.) Clamp the cell
book press or put a flat heavy piece on it to hold it closed while the
solvent evaporates and the plastic hardens.
14. Use heat glue to seal the "+" terminal slot, including some between
the zinc and the plastic tab.
15. Punch a hole in the graphite and in the zinc terminal, put in brass
stainless washers and machine screws and nuts. Loosely put on a second
nut to attach connection wires.
16. Fill with electrolyte pouring from a beaker, using a fine funnel,
small flex hose or ?.
Liquid level should be above top of grid. (If you can find translucent
or transparent plastic for the flat face, its great for seeing the
level! Note: acrylic
plastic will crack to pieces if it contacts toluene.
17. Place 5/16" ball bearing on filler opening and put cover clip over