Dyson Vacuum Kobalt Battery Adapter

Adapter to allow you to use a Kobalt(Lowes) 24V battery with your Dyson V8 Stick Vacuum. Will probably work with other versions of Dyson vacuums. Allows you to use longer lasting batteries and quickly swap to a freshly charged battery when another dies. 

The Kobalt and Dyson stock battery both have a 21.6V nominal voltage, so the vacuum will have the same amount of suction with the Kobalt battery as it does with the stock battery. Most other brands of tool batteries have a 18V nominal voltage and the suction is noticeably less when using these lower voltage batteries. The vacuum pulls a lot of current(~20A) so I would recommend the 4Ah Kobalt battery, these will also give you more runtime(40%) than the stock 2.8Ah battery and will probably handle the current better than the 2Ah Kobalt batteries.

The adapter is the same size as the battery so you can still use the stock vacuum wall mount as long as the Kobalt battery is removed. 

Additional items needed:

1. 6 M4x10 screws
2. 14AWG or thicker wire
3. 3 male blade crimp connectors
4. 5 female bade crimp connectors
5. High current switch (≥20A), I used a C1300AABR from Digikey

2 of the male blade connecters are used as the contacts for the battery. They are clamped to the lower body using the clip piece and 2 M4 screws.  

2 of the female blade connectors are used to connect to the vacuum's terminals, these connectors will need to be made slightly bigger with a flat blade screwdriver in order for them to fit over the vacuums terminals. 

The other connectors are used for easier assembly allowing you to wire up the 2 pieces separately before assembling together. 

Thanks to TeachingTech for a great starting off point on the design.

UPDATE:

After using this for almost a year a couple issues came up. 

First the top of the upper body broke where the screw holds it. I uploaded a new upper body model that has more material around the hole to make it stronger. 

Second, the contacts with the battery eventually shifted to a point where they no longer made contact. They were getting hot and deforming the PLA I printed this in. Because of this I would recommend you print this in PTEG or ABS to better handle the heat. Also I found that an easy way to get the contacts mounted in the print was to get them in the correct location, attach the clip and tighten half way and then get a soldering iron and heat the contacts up so they melt into the print. Then tighten the clip all the way. They were very solid after I did this. 

Designed for Kobalt batteries instead of Ryobi