Homemade Test Jig for eGo Batteries and Attys.

rowdyplace;12059114 said:

I wanted a tool to measure the resistance of attys and another tool to measure the output of eGo batteries.
Using a connector from a battery, and also an old atty, I built one of each. (Left side and Right side of this drawing.)
Use a eGo battery and a Ce5 atty that you don't mind ruining. They will never be usable for their original purposes.
Proceed with caution. This is what and how I did this. If you try this, it is at your own risk. I accept no responsibility for your damage or losses. Do not try this if you are unfamilier with soldering techniques - or the correct use of a multimeter. You could hurt yourself, or worse... Your milage may vary!

Atty Resistance Measureing Tool:
Starting with the battery, turn it "off" and remove the "head". Pull the top part like crazy while rocking it back and forth from the lower (longer) part. Mine popped open and tore the thin wires apart - but, that's OK. Properly discard the electronic assembly and the battery. Save the lower part. Using the "head", gently push the battery center post out. Solder a long (your choice) red wire to the center tab of this center post making certain you do not slop the solder over the edge of the post. It has to fit easily back into it's original location. (OPTION - Insert a #60 o-ring on the red wire before inserting it back into the "head". This has the center post sitting on a little springy do-nut, and prevents the typical problem with the center post getting stuck too far down.) Now, solder a long green wire to the common side of the "head". Drill an appropriate hole in the bottom of the lower part (battery removed), and insert both wires through the hole. Re attach the "head" to the lower part. Your project should look like an eGo battery with a red and green wire hanging out.
This is your atty resistance measuring tool. Connect the red and green wires to an ohmmeter and screw an atty onto the "head" to measure the resistance.

Battery Voltage (Static) Measuring Tool:
Inspect your old attys looking for a Ce5 (bottom screws on/off) with a good center post that sticks out somewhat. Mine had a springy feel. Remove same using needle nose pliars being careful not to damage it. Solder long red wire to this center post being careful to not slop solder over the edges. This must slip back into it's original location. Remove mouth tip, top plastic portion, and the wick and coil assembly. Discard coil and wick stuff and save the plastic parts. From the atty bottom, push a small stick, bolt, whatever upward to clear out any remaining wick/coil stuff from center shaft. Solder a long green wire to the inside of the common portion of the atty. From the bottom, re-insert the red wire into the center hole making sure the center post fits correctly back into it's original location. Slide the top plastic portion and the mouth tip over the wires and screw each back in place. Your project should look like an atty with two wires hanging out.
This is your battery voltage measuring tool. Connect the red (positive) and green (negative) wires to a voltmeter, attach an eGo battery, press the button, and observe the battery static voltage. (This is the "no-load" reading and has very little value.)

Dynamic Battery Voltage Tool:
Using the 2 tools above, connect the red wires together and connect the green wires together. Set voltmeter to VOLTS! Attach live battery and live filled atty to appropriate connectors. Press battery button, and you will see the battery's voltage under a "load". This is the best way to check a battery.

(I made my wires long enough to be able to place the atty in my mouth and take a puff or two.) You do not want to burn out the coil of scorch the juice. Repeat this test several times to view battery voltage. Dropping voltage means weak battery.

Using different connectors or adapters will allow this to be used on other style e-cig devices.

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(Not sure how to make this drawing larger...)​

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