First things first. As I already ordered nimh batteries, I will try to solder them on lowest temperature settings.
Hope it will not melt seals. I will see if those batteries will hold charge and let you guys know...

 

First things first. As I already ordered nimh batteries, I will try to solder them on lowest temperature settings.
Hope it will not melt seals. I will see if those batteries will hold charge and let you guys know...

I suggest using a mechanical method of holding the battery connections in place. And perhaps somebody reading this thread has created a capacitor discharge welder design that they would share. The welds do not need to be very big or strong, a drop of epoxy can hold thins in place after they are made.

 

I suggest using a mechanical method of holding the battery connections in place. And perhaps somebody reading this thread has created a capacitor discharge welder design that they would share. The welds do not need to be very big or strong, a drop of epoxy can hold thins in place after they are made.

What about super glue with baking soda?

 

What about super glue with baking soda?

I was thinking more in terms of a plastic frame, brass washers, and rubber bands. OR, possibly, just use the same enclosure as the original battery pack, with bent spring pieces to connect the battery ends. And the jumpers can be held in place by some instant epoxy in the area where they are not contacting the cells.