This mod details how to build your own iPod External Charger for your 1G/2G/3G/mini iPod. The system lets your run, and charge your iPod from 8 "AA" batteries.  Allen Evans recommends it for travelers, or anyone who needs a versatile charging method and does not want to drop big bucks on a commercial charger (like the Belkin model for example).  Allen also has a copy of this mod on his site.  Warning if you decide to read more, this mod contains a lot of images and may take some time to load.

This is for the 1G and 2G iPods.  But it should work for the 3G+ iPods by using PocketDock availalbe here.

Parts to be used:

@ 2x RadioShack Fully Insulated 9V Battery Snap Connectors -> RadioShack Number: 270-325 ($2.98 each)

@ 2x RadioShack "AA" Battery Holder - Holds 4 "AA" Batteries -> RadioShack Number: 270-383 ($1.99 each)

@ 1x RadioShack Heat-Shrink Tubing [Tubing will shrink when blown on with hot hair dryer air]- Package of 12 -> RadioShack Number: 278-1627B ($2.00 each ??)

@ 1x 6-to-6 Pin FireWire Cable [I used: XtremeMac Xwire GOLD FireWire 1-Foot Cable -> SmallDog Electronics Number: G/XTR XWF1F02 ($9.00 each)

@ 1x Roll of generic black Electrical Tape ($2.00 each ??)

@ 1x Some sort of case (about 2.5" x 2.5" x 1.5")... contact me if you have ideas for this!

Procedure:

Everything below assumes you have bought the exact same equipment as I did. If you did not, please make sure to change this procedure accordingly!

Carefully slit the rubber/plastic insulation on the cable to expose the metal shielding underneath.

Flip the wire over and do the same.

Carefully cut through the metal shielding wires (these don't transfer any electricity when cable is in use).

Cut through both ends of the exposed metal shielding wires so they can be disposed of, and four new wires are showing.

Cut off the rubber/plastic insulation from the cable.

Now identify the data cables (the two sets with two wires in each set) and cut them off with only enough wire sticking through so that they can be insulated... note: these are NOT the white and black loose cables!

Now strip the ends of the two power wires of the cable. Also strip the ends of both of the wires on two of the RadioShack Battery Snap Connectors.

Attach (via twist together method/soldering/whatever you want) the red wire from on of the battery snap connectors to the black wire on the other battery snap connector. Put a Heat-Shrink Tubing of appropriate size on the connection and shrink it. You may want to put some electrical tape around the bottom of the Heat-Shrunk Tubing. This connects the two battery packs in series.

Now you need to insulate the ends of the cable data wires you cut earlier. Do this with the Heat-Shrink Tubing again.

Now put a larger piece of Heat-Shrink Tubing over the end of the cable, leaving just the power wires exposed at the end.

Now your FireWire cable should look like this:

Its time to link the cable power wires to the battery packs. Connect the negative power wire to the negative FireWire cable negative power wire. You are connecting the only loose black wire from the battery pack to the black wire coming out of your FireWire cable end. I recommend soldering this connection. Place Heat-Shrink Tubing over this connection and shrink the tubing.

Then do the same with the positive wire. Connect the positive power wire to the positive FireWire cable positive power wire. You are connecting the only loose red wire from the batteries pack to the white wire coming out of your FireWire cable end. I recommend soldering this connection. Place Heat-Shrink Tubing over this connection and shrink the tubing.

Now your FireWire cable and batteries should look like this:

You can (and I recommend) putting all your connections together and Heat-Shrinking them. This will just help keep your connections from ever coming loose.

Put electrical tape around the base of your Heat-Shrunk tube because there are so many wires it would be easy for them to come loose at the bottom without this.

Your setup should look like this now:

Add batteries:

Your Finished Product:

Finished Product in a case I found:

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