Here is how you do it with NiMh or NiCd cells - it takes an attachment to a soldering iron these guys call a hammerhead. The article shows you how.

http://www.offshoreelectrics.com/pro...d=ose-38hammer

I don't think that is how you're supposed to do a123's however. Thats why I asked, I knew you were asking that too. Maybe someone will enlighten us??

I see a lot of them used as stick pacs and suspect they're just bending them back on each other using the dewalt connectors that come out of the pack. Neil was telling how the end to end pairs were connected.

another option for making stick packs from a123. No slodering required.

http://www.modelelectronicscorp.com/...uct.php?pid=29

I used the existing connections when the cells are end to end- they are fairly thick metal tabs so can handle the current just fine. You could always used that copper braid stuff to 'beef-up' the tabs though.

Nice option, more reasonable that the ones that use the metal tubes!

Neil, one of the guys on rcgroups tested the existing connection - they are plenty good enough. No need to expose the cells to more heat. My 5s1p a123 packs use the existing connectors and are fine - have never noticed any more heat at the ends that anywhere else on the batt. Side by side they are too big to fit on my G2R.