Modernizing the Makita 9.6 volt tools

[bonneyman]

The recip is the one tool I never got from Makita.  I remember wanting one, but thought they were expensive.   Instead I did consume one & then buy another 3-3/8" circular saw.  Long before oscillating tools for cutting in elect. boxes & even trim work. 

The clutch system in the 9.6v drill/driver was far ahead of anything else available at the time.

Oh, I hated those things! Especially as they got older and worn in - they'd slip at the littlest amount of drag.
I've taken one of my clutch-equipped drivers and jammed a spacer inside to try and lock the mechanism together and delete the clutch. Only partially successful. Thinking about grabbing another drill and welding the two slipping halves together so there is no slip. Another project!

[bonneyman]

Time for some more upgrades!

After looking over my previous hanger options I decided to improve upon them. Most new cordless tools have built in hangers. Typically heavy-gauge metal clips that hook onto a belt or waistband. I picked up some of those in previous thrift stores and pawn shops, thinking they might prove useful for something. (Mainly I was thinking I could screw them to the wall and hang something loose from them). Having several kinds I thought, "Why try and re-invent the wheel? Perhaps I could modify and use them on the Makita's?"
Here's my first attempt. The attachment holes don't really line up with the screw holes in the handle, but with a metal bit can be adapted. This unknown hook is the heaviest of the ones I have. Took some metal spacers and longer screws and put it together.
Doesn't look too bad. The battery spring cap means it has to be a bit further out from the tool than I'd like, but can't be helped. Perhaps a bent sheet metal guard will be needed to allow the user to slide it over a belt without the rubber impact buffer pin from catching. It isn't in the way when using the light, and might prove even better on a heavy drill.

[bonneyman]

Continuing on with the belt hook idea, I decided to do a quick and dirty basic wire hanger using the little wire bending jig I was gifted with. (It's alot harder than it looks)! This little detour gave me an idea of what the minimalist approach might look like.

It's not perfectly straight, and I think I might make it a little shorter and with thicker wire. But I like the look of it - and it goes along with the OEM wire stand on the bottom.

[bonneyman]

Well, we have another Makita mod to show!

Sorry that's it's taken so long for update. My heart condition has been kicking my butt, and the fatigue has been awful. But finally am feeling better and able to get out to the shop.

I'm a big fan of the Makita 9.6v flashlights. Just fit the hand nice, solidly made, and constructed of ABS so it's easy to fix and mad. I snagged this beater some time ago before I had gotten back into the line serious like. Didn't have any stick batteries or chargers at that time, so modified this light to run off on 9 volt transistor batteries. Worked well.
I have since picked up a handful of flashlights, most missing parts. That makes them obtainable for a bad song. When deciding to do a light mod I decided to make my old transistor battery the "donor" for OEM parts, and swapped out all the substandard pieces and/or made replacements. The newer lights got all the OEM parts, and this one became a "mutt" tool.

I wanted to add a carry handle to the flashlight to replace the cheapy plastic OEM strap. One of the few design concepts Makita did which I don't like. Anyway I wanted to add a wire handle that would look like it went with the light and not alter the base tool in any way so I could always put it back.

[bonneyman]

Adding a folding handle wasn't too hard - I thought. Not wanting to cut or damage the light in any way I had to disassemble it and figure out how to add the handle to the existing structure. Finally settled on making some stainless steel straps that would interface with the carrying strap mounts, then attach the wire handle to it. Figured I'd then add a belt clip attachment like I'd already done.

....But then I thought, "What if I could incorporate a hanger into the wire handle? Kill two birds with one stone". That took some doing. Finally settled on a loop end in the wire handle to hook onto a belt clip. Will work right or left hand, when folded out of the way it gives plenty of hand clearance, with a rubber grip ta boot. Made from a 5-gallon paint bucket handle it will surely handle the weight with a stick cell. I might still add a coiled wire stiffener near the end loop and paint it. We'll see how it goes. And if the belt clip thingy doesn't pan out I have another wire handle prepped with no added loop. So, I think I'm covered. Worst comes to worst it doesn't hold up or the ABS mounts break. Then I'm back to a mutt light that works anyway. So no prob!

Here is the result: