Wood Padauk, Aluminum and an interesting micro switch

[BlueridgeDog]

Done with the Wife's purple heart mod, on to one (another one) for me. This is Padauk skins with an aluminum case, blacked-out Lexan screen cover, dual bag lipos and a very interesting dual tactile switch that I just love.

After using her dual lipo rig, I really like the power, weight and battery life.

 

[Podunk Steam]

That dual tactile is interesting. Nice job!

 

[Davantrac]

One of the best I've seen for sometime.

 

[BlueridgeDog]

Thanks. The dual tactile is here:

TL2243 E-Switch | Mouser

I am going to try a few different designs to take advantage of it.

 

[Dougiestyle]

Please shed some light on where the aluminum frame is sourced. I like that.

 

[BlueridgeDog]

Sadly the frame has to be made. I take 1" stock and braze it after doing the openings etc.

 

[Obsiden]

Looks awesome...how did you close the 4th corner?

 

[WharfRat1976]

Love to see a gut shot if you'd care to share one.

 

[Davantrac]

I quick side question about the dual switch. I haven't started building yet so haven't even seen the single switch up close. If the button is too long can they be filed or cut down a couple of mm?

 

[BlueridgeDog]

Looks awesome...how did you close the 4th corner?

I use aluminum brazing rods.

 

[BlueridgeDog]

I quick side question about the dual switch. I haven't started building yet so haven't even seen the single switch up close. If the button is too long can they be filed or cut down a couple of mm?

I have cut some and sanded some. I would recommend sanding them, but yes, you can shorten them. I may shorten these by 1.5 mm.

More commonly I use a spacer, say another layer of aluminum to increase the depth. I have put the spacer on the back and on the front. The front makes an interesting look, better than you would think.

 

[BlueridgeDog]

Love to see a gut shot if you'd care to share one.

Will do...eventually. The skins are back off for finish application but when it is back together I will share the inside.

 

[something_vague]

Very nice looking device. What is the chip that you're using in this device? I didn't see where you mentioned it so forgive me if I missed something.

I would also be interested in seeing an up close of where you braised the seem. I have never used a complete piece of metal all the way around any of my mods but really like the look that gives depending on how good of a job I could braise.

 

[BlueridgeDog]

The chip is the DNA 40 large screen...only one I like now days. The braze joint is invisible after sanding and putting a 220 grit brushed finish on the aluminum.

I use this: Aluminum Welding Rods - Pack of 8 Low Temperature Rods and a propane/butane or map torch.

It is picky stuff to use, but after some time you get the feel of it. It is also very hard, so you want to limit the amount you have to grind off. Typically I leave the last leg long so that there is some adjustment for square and the final is a T .... join that is then sawed off and ground to a curve to match the other corners. It is also more or less essential that all the case work be done when the metal is flat.

I am still not happy with the screen cover/glass you can get with standard home tools, so I am going to use a blacked out lexan sheet for backer, then pour two part resin to fill the cavity, alleviating the need for a perfect fit on the lexan.

 

[BlueridgeDog]

There are some closeups of the braze joints in aluminum in this post:

Smallish Aluminum and Purple Heart Mod | E-Cigarette Forum

 

[vapero]

great work!!

 

[sonicbomb]

Very handsome mod, aluminium and wood works for me at some deep level

sent from my G3 using Tapatalk

 

[BlueridgeDog]

Thanks. I am now working on a smaller mod, with larger gauge aluminum and burled stabilized wood. It should be amazing.

 

[Davantrac]

Can't wait to see the new one. Small ally and wood mods are my favourite, just love the clean lines.
If you ever want to donate one to a good cause I'm here

 

[BlueridgeDog]

Milled, brazed and polished the band for the stabilized burl mod today....it will be tight...it is smaller than the purple heart wood mod I made, but will work in theory.