I've had a DLI90 battery swell on the flat sides and get jammed inside
the camera.
So I first googled and found out what was inside the plastic shell.
Found it had two Lithium cells
connected to a tiny motherboard sitting on top.
So using a drill without caution would go through the motherboard and
perhaps cause problems.

So I used a craft drill with a 2 mm drill bit at slow speed. I wrapped
a colored electrical tape 1.5 mm
from the tip which was about the thickness of the battery shell.

Drilled gently to puncture the shell without touching the motherboard.

Bent 2 #s 2 mm thick steel strip into L-shape and stuck them on top of
the battery in a T-shape with
Araldite Epoxy - slow curing type. Let it to cure for 24 hours.

Then drooped just a wee bit of Singer Sewing Machine oil on both the sides.

Grabbed the steel strip and slowly pulled out the battery.

The battery shell was swollen on the camera contact side.

Before scrapping it I dared to charge it on a cheap ebay charger. Then
checked the voltage. Eureka
8.4 volts. Checked for heat build up and there was none.

Peeled the sticker on the swollen contact side and rubbed it down on
an Emery Sheet. Put it inside
the K-5, and voila the camera showed Full Charge and it was working.

Better sense got hold of me and I scrapped this 3rd Party 3-year old
battery. Had won it on an evil bay
bid for $ 3.99. Lesson learnt - use good quality stuff like DSTE or
Wahabi for $ 6 to 9.

Note: I have used some (9) #s 3rd Part Batteries on my K-20D, K-5 &
K-5 IIs with just this loss.

Regards.
Bipin

Photography focuses you to see things you may not notice otherwise.

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