Kobalt 40v battery to Greenworks tool adapter

This print, shown in gray/silver, allows us to use a 40 volt Kobalt (Lowes Home Improvement store house brand) battery with a 40 volt Greenworks tool, but only the tools that carry the batteries externally. My Greenworks blower works and it looks like string trimmers and hedge trimmers will work. But tools like lawnmowers and chainsaws dont look like they'll work from photos I've seen on the 'net because they partially enclose the battery and the Kobalt battery is much wider than the Greenworks battery.

The main unit is designed to slide into the tool and stay there with a tight fit while the battery can be freely attached and detached by sliding it into the main unit. The battery makes an automatic electrical connection by sliding onto spade connectors glued in place. One caveat is that the slot for the battery lock, while it keeps the battery secure, requires a flat screwdriver to lever the battery out for charging (see photo).

After printing the main unit you also have to figure out how to make the electrical connection. The main unit has a slotted hole in which to insert the 10/12 AWG spade connectors mentioned previously, whose yellow jackets has been removed (see photos). You must insert the blades into the slotted holes then give them a 90 degree twist so that the non-centered blades sit to the outside of the center line of the holes. This will allow the Kobalt battery to slide in and make the electrical connection. After assembly with the battery connected I suggest using epoxy to lock the blades in place (see photo).

For the tool side, the main unit doesn't have a dedicated electrical connection scheme. If you choose to connect like I did print the second unit, shown in dark blue/green, a small U shaped bracket that holds the blade clamps salvaged from a North American wall plug (see photos). This separate unit is attached to the tool having already put the wires on the screw terminals before sliding the main unit on the tool and completing the connection by soldering on the blade connectors. This is a little fiddly but you only have to do this once since the main unit stays on the tool.

Suggestions for improvement welcome!

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