Modding w an eGo pcb...

[JZXJ]

Now I'm looking for mechanical relay that can handle 3 amps and still be small enough to fit in the tube... AND not cost a fortune! (starting to think it may not exist)

isn't 2A enough? http://www.gatewaycatalog.com/cgi-bi...348&type=store

Could you forego a relay and just use an industrial grade moment-micro switch?

[jasl90]

2A would be fine most of the time. My biggest concern w/ a 2A relay would be longevity.
A freshly charged battery would kick out 4.2 volts which means that I'd hit the 2A limit with a 2.1 Ohm atty. A Cisco 1.5 would push it all the way to 2.8A.
I'm by no means an expert, but I've always been advised to select a device w/ double the amps rating of what you expect to need. Since a 5A or 6A relay is simply too big that's not an option.

As momentary switch... I've never seen a tack switch rated more than 50mA. The larger 3A momentary switches are either ugly as hell and stick out too far, or too expensive.

If I could find a good deal on something like this, I'd be all over it...
metal switch.jpg

[jasl90]

Maybe this one...
Heavy Duty Momentary Push Button OFF(ON) SPST Switch 6A | eBay

[meatsneakers]

Have you consider a snap-action switch? Miniature snap-action switch - Wikipedia, the free encyclopedia

They're my favorite switch type - Digikey sells hundreds of them that handle high amperage, they have a satisfying click and they are cheap. The only issue is finding a button to activate it - you can use your imagination though. I've used the actuator from a tactile switch to a pin from a shelf hook: http://www.homedepot.com/webapp/wcs/...5f%2d100544240

Just hit that pin with a hammer and it pops right out - makes the perfect button for a snap-action switch.

[jasl90]

Now you're talking!
Saw some 5A versions on eBay for $2.
May have to go ahead and pull the trigger.

[KeithB]

You can remove the protection board from the battery. It positioned on the bottom. eGo board itself has enough abilities to protect the battery.

YOu could take the airbags and seatbelt out of your car too, but I wouldn't recommend it.

While the MOSFETs in the eGo boards usually fail in the open/off mode (when they fail), they have been know to fail in the closed mode. I'd want to have the additional protection of the PCB myself, just in case.

[Vaptor]

Li-ION is normally only 1C discharge. If you want more you need LIPO. You can get up to 60C now days but are more volatile. Mostly used in RC for a Ton of power.