I had some older HP servers at work with Ni-MH batteries that kept bulging, and reporting as failed. Anyone in this circumstance knows that if you order a new battery, you are either getting a seller refurbished (aka they didn't do anything because the new batteries are bulging too) or you get new old stock batteries (aka batteries that have been sitting around with a partial charge for at least a decade now and probably bad).

Luckily some cool people on the internet pointed out that you can get a quad AAA pack of Ni-MH batteries, and it will be the proper voltage, slightly more current, and is still capable of being charged by the onboard circuitry.

Enter this design which should hold the daughter board card, cable clip, and battery pack in a nicely pressure fit package, with easy to replace batteries.

My setup:

• 4x AAA NiMH batteries; 1.2V, 800mAh
• 1x quad AAA holding pack
• Solder
• Glue or Double sided tape (optional)

Suggested print settings:

• 30% Infill ; You can probably use less. YMMV
• 3 Perimeters
• 0.20mm layer height
• No Supports ; All parts should be bridgeable. Even if they are not pretty, they should work.
• PETG or other higher temp plastic

Prep and Connectivity

• Pull the charging circuit from the HP module
• This is simply held in with a plastic clip. Break or bend it slightly to pop the board off.
• Carefully insulate the pins for the battery and dispose of properly.
• Seriously, do not throw these batteries away.

Prep the daughter board and pack holders

• Remove the small standoffs on each side that supported the bridged ends for where the cable to the RAID card clips into.
• Dry fit the board into the holder.
• Look for and verify the + and - symbols on the board for the batteries.
• Run the battery pack wiring through the respective holes and then solder them to the daughter board.
• Clip the board into the holder. You may need to flex it a bit to get it to snap in.
• Route the wiring harness through the pack holder.
• Connect the wiring harness going to the RAID card.
• Insert the daughter board holder into the pack holder
• Carefully route the battery pack wiring down the side and under the pack.
• Everything should pressure fit together but can be glue or taped if needed.
• Insert the batteries, paying attention to orientation.
• Reconnect back to the server. Use double sided tape if you wish to keep the pack in place.
• Boot up and pray there is no magic smoke.

NOTE: This was copied from thing:4858191 due to thingiverse bring broken, and not responding to my support request. That thing was updated to reflect this thing as well.