• One of the problems is that the charger is needed along with the base to properly charge the Dremel so fitting just a jack will not work.
• It doesn't make sense to carry a base and a charger separately that cannot be disconnected from each other so it's a good idea.

An idea is to fuse the charger and the base together for an all-in-one solution. Clearly, a box is needed in order to fit both components and to relocate the circuitry. Furthermore, the Dremel base is a solid mold that will have to somehow be cut up and then fitted onto the new box.

Chop-chop, using the Dremel itself, the base is hacked into pieces in order to hopefully extract the plastic socket intact. It was pretty difficult, the insides that are not pictured here contain various plastic shapes that are part of the internal structure and the PCB is actually not screwed onto the bottom of the socket, but rather held up by some struts that had to be removed.

We were able to procure some very cheap junction boxes from Italy and they are pretty appropriate given that we're going to move in the power supply inside the box itself as well as mounting the socket into the box.

Of course, there will be paint involved, so the plastic was scratched a bit in order to allow the paint to grip into the plastic when it will be painted.

A hole is drilled into the new box as well in order to fit the Dremel socket and faceplate inside.

Let's see... The Dremel is represented by the color blue, tints of grey, white and black and sometimes shades of purple when the powertool lights up.

Tada! Compared to other times, the box was primed with fire retardant, which is not a bad choice considering that these power supplies sometimes tend to go up in flames. It is not a bad result, the blue on the socket and faceplate definitely stands out nicely. However, the primed box will be painted over black for a darker shade. First, here's a preview how this new gadget will look like when it's completed.

Tada! Of course the socket could have just been glued onto the box, but hey there was room for four screws, and it definitely looks better with the screws holding the faceplate down.

Now with the painting out of the way, the circuit has to be moved inside the box. This means cannibalizing the Dremel power supply and finding a way to mount the charger circuit on the bottom of the socket cutout. The mounting struts were cut while carving the socket out so new ones have to be created. Interestingly, we settled for creating struts out of PCB leftovers that were first soldered together and then glued.

In many ways, the results are somewhat better than the original because we use screws to mount the charging plate onto the bottom of the carved-out socket, which means that compared to the original, there is way more stability and it's also easy and convenient to remove the charger PCB if needed.

The original Dremel solution ended in the charger containing the power supply with a three prong UK socket.

The three-prong UK socket however had the middle strut made out of plastic instead of metal such that the charger did not even benefit from any grounding. With that said, we'll replace the bulk with just one removable cable with a small two-prong socket making the result more portable.

There is room for everything inside the box and the circuitry is actually very simple. The LED was reworked; pulled out, a JST jack fitted and then the LED was glued to the box. We chose a purple LED.

The yardstick here is the blinking LED because the Dremel battery charges when the LED is blinking.