I don't have expertise on NiCad batteries, but forging ahead fearlessly anyway with the question: Would it be possible to make a NiCad battery similar to Optima spiral wound design? Lots of plate surface area, low resistance -- this might make for quite a high power battery. Maybe this would be something that could even be made in a garage? You might be able to make a "box spiral" or "zig zag elecrodes" or "interleaved electrodes" out of old nicad battery parts. If I understand right, the electrolyte doesn't really participate in the reaction, just acts as a charge carrier, so it seems you would not need much electrolyte. What sets the minimum bound on how much electrolyte a nicad needs? Time between refills?
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