I use a dremel cutting wheel to open batteries. The Zinc (if it's a zinc-carbon battery) outer shell and carbon rods you might want to keep, because they can come in handy.
In my Bio class this year, my teacher was giving a lecture and had a can of potassium on his desk (he teaches chemistry too). He asked us if we had ever seen it put in water, and some hadn't, so he took out a couple pieces and put them it water and we watched it burn (cool purple flame). A nice little break from the lecture.
Ebay is a good source. Here's 6 pounds for $16 including shipping - http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&category=2567&item=3857109258&rd=1
I got some from this seller. Good stuff.
HCl you can get at a hardware store, its called "Muriatic Acid" and it's used for cleaning things like stone. I've seen H2SO4 at Home Depot, sold as battery acid for sump pump backup batteries.
I Zinc plated a penny the other day. I dissolved some zinc in some HCl, then connected the penny to the negative terminal of a transformer (18V, 2.23Amp, not sure if it matters) and another chunk of zinc to the positive terminal, and placed both of them into the Zinc Chloride solution. It worked rather well, put a thin layer of zinc onto the penny.
I found a bunch of zinc-carbon batteries in the clearance rack of the hardware store a while ago. Unfortunately, I bought them for the zinc and threw out the MnO2.
I once decided to electrolyze some water, and I caught the hydrogen and oxygen in a sandwich baggie. I wasn't expecting much, so I lit it in my basement. BOOM! Really loud, more than I expected. Encouraged by this, I decided to do it again, but with a gallon baggie and do it outside. Sounded like a shotgun going off. Ah, chemistry is fun.
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