AAA 3.6v (4.2v fully charged) Battery Box mod with a twist!

[opusMorian]

Still disappointed with my screw driver parts not arriving, I decided to do a battery box mod that I have seen on the forums. I am not taking credit for the battery box idea, I just made it a tad better.

I am not going to do my usual full blown instruction since this is probably 1 out of 5 difficulty level. I will, however, post pics of the inside here.

let get this out of the way first.....
DISCLAIMER: I am not responsible for any personal (including mental anguish) and/or property damage. Try this AT YOUR OWN RISK! There is no warranty or guarantee of ANY KIND! If you have any question at all to the safety or validity (or anything kind of concerns) of any steps/procedure, STOP NOW AND DO NOT TRY ANYTHING!



Introducing, the AAA 3.6v-4.2v Battery box!

Here are the radio shack part I used and the battery:

The battery is from here:
DealExtreme: $4.32 Ultra Fire 10440 3.6V 600mAh 2Pack
At 600mah, it will last more then three times as long as the dse901 OEM batteries (around 180mAh even though claims 250mAh) . I know it is not much, but you will see its benefit later.

Here are is the AAA battery box mod....

Here are some pictures of the inside.

 

[opusMorian]

Here is why I wanted the AAA (the twist)....

The atomizer and the cart fits INSIDE!!! You can carry this around without stabbing you in the ***t when you walk.

Enjoy...

 

[Sun Vaporer]

opusMorian--Very nice Mod--How is that 9.5mm Tact Switch holding up--any issues with the load on it? Sun

 

[opusMorian]

opusMorian--Very nice Mod--How is that 9.5mm Tact Switch holding up--any issues with the load on it? Sun

Thanks!

The tact is holding up well. I start to be concerned about it after a forum member made me realize that it was only rated at .5amp. I've since been using the switch constantly on 3 different mods hoping I can get some indication that it was burning out or failing. Up to now I have not have any issue at all.

 

[Sun Vaporer]

Thanks!

The tact is holding up well. I start to be concerned about it after a forum member made me realize that it was only rated at .5amp. I've since been using the switch constantly on 3 different mods hoping I can get some indication that it was burning out or failing. Up to now I have not have any issue at all.

Opus--that switch is very good even though it is small. How are you getting the Postive of that battery to connect to the contact of the box without cutting away the plastic as the Trustfire batteries do not have a positive terminal that sticks out like other AA types and is almost flush? So how is it making the contact with that gap in the plastic? Thanks--Sun

 

[opusMorian]

Opus--that switch is very good even though it is small. How are you getting the Postive of that battery to connect to the contact of the box without cutting away the plastic as the Trustfire batteries do not have a positive terminal that sticks out like other AA types and is almost flush? So how is it making the contact with that gap in the plastic? Thanks--Sun

I see that you have played with these batteries before. It simple, just extend the positive terminal plate on the battery box with extra solder. Just make a small rise with the terminal plate that suppose to make contact with the positive terminal and it will work fine.

 

[Sun Vaporer]

I see that you have played with these batteries before. It simple, just extend the positive terminal plate on the battery box with extra solder. Just make a small rise with the terminal plate that suppose to make contact with the positive terminal and it will work fine.

Opus --I did a 3AAA box using that same tact switch and have been using it now for well over a month without issue-- I have been using the Nicad rechargables, but now have the Trust Fire and am moving to this style--like how you have the other side for holding the atomizer and cartridge--that is brilliant!! I used gule on that tact switch --what do you have their holding down the switch? --Thanks again---Sun

 

[fenez]

That mod is sweet I ordered that battery & now I know what mod to make with it awesome job my friend

 

[nicowolf]

Thanks!

The tact is holding up well. I start to be concerned about it after a forum member made me realize that it was only rated at .5amp. I've since been using the switch constantly on 3 different mods hoping I can get some indication that it was burning out or failing. Up to now I have not have any issue at all.

I have a question I've been meaning to ask since that forum member started that whole debate. I guess it's time to bite the bullet and ask. Does it make a difference that we are working with 3-6 volts in our mods and the ratings for these switches are always done @125 volts AC and/or 12 volts DC? I mean if it's rated, say .5amp at 12 volts DC, wouldn't that be 1 amp at 6 volts and 2 amps at 3 volts? I am not sure how that works, but it might explain why we have so little problems using these.

 

[opusMorian]

Opus --I did a 3AAA box using that same tact switch and have been using it now for well over a month without issue-- I have been using the Nicad rechargables, but now have the Trust Fire and am moving to this style--like how you have the other side for holding the atomizer and cartridge--that is brilliant!! I used gule on that tact switch --what do you have their holding down the switch? --Thanks again---Sun

No problem! I am glad to share with fellow modders. I am using this glue gun that I got from the dollar store to hold that switch. Cheap and effective. Was thinking about using epoxy, but don't think the lingering fumes would be a good idea to inhale.

 

[fenez]

Hey nico I hungout with spikey last night, love the pic

 

[nicowolf]

Hey nico I hungout with spikey last night, love the pic

Lucky dog.

 

[fenez]

she is an absolute sweetheart, she is so much smaller than I thought she would be, and yes she is very pretty in person as well.

 

[fenez]

No problem! I am glad to share with fellow modders. I am using this glue gun that I got from the dollar store to hold that switch. Cheap and effective. Was thinking about using epoxy, but don't think the lingering fumes would be a good idea to inhale.

would a two part epoxy work or is that no good for this application?

 

[opusMorian]

I have a question I've been meaning to ask since that forum member started that whole debate. I guess it's time to bite the bullet and ask. Does it make a difference that we are working with 3-6 volts in our mods and the ratings for these switches are always done @125 volts AC and/or 12 volts DC? I mean if it's rated, say .5amp at 12 volts DC, wouldn't that be 1 amp at 6 volts and 2 amps at 3 volts? I am not sure how that works, but it might explain why we have so little problems using these.

I ripped apart a 120vac momentary switch and also a 24vdc momentary switch that looks about the same and from the same maker. The difference I saw was that the contact pins inside the 24vdc were thinner and flatter then the 120vac one. Since we are only working with 3.6vdc at max 1.2amp draw, I don't see how it would make that big of a difference. But since I am not an electrical engineer, I hope no one takes this as an fact.

I am also hoping some electronic guru/engineer would tell us the difference and will we blow anything up from prolong use.

 

[opusMorian]

would a two part epoxy work or is that no good for this application?

Yes, I think any epoxy will work, I was just worrying about the lingering fumes.

 

[Sun Vaporer]

I have a question I've been meaning to ask since that forum member started that whole debate. I guess it's time to bite the bullet and ask. Does it make a difference that we are working with 3-6 volts in our mods and the ratings for these switches are always done @125 volts AC and/or 12 volts DC? I mean if it's rated, say .5amp at 12 volts DC, wouldn't that be 1 amp at 6 volts and 2 amps at 3 volts? I am not sure how that works, but it might explain why we have so little problems using these.

Nicowolf--I know of the debate you speak to. I have been using this switch at a 50ma 12v dc rating now for well over a month without issue--so the rating is obviously flawed or not stated properly ---it is a 9.5mm High Tact Switch by Radio Shack, part number 275-0003. Comes in a pack of 4 for a few dollars--give one a try and let me know how you make out---Sun

 

[H82W8]

I noticed that the battery is an unprotected model so there is nothing to keep it from over discharging. Is that going to be a problem? I'm no expert but struck me as a possible problem.

Love the idea BTW

 

[nicowolf]

yeah, I am hoping someone who knows this stuff can speak up as to whether that makes a difference. I think our mods are not taxing the switch as much as higher voltage would. The switches I have been using are rated .3amp at 50VDC. I think that would mean 3amps at 5VDC, which would be twice what we need. Could some electric guru please chime in and help us?

 

[nicowolf]

Nicowolf--I know of the debate you speak to. I have been using this switch at a 50ma 12v dc rating now for well over a month without issue--so the rating is obviously flawed or not stated properly ---it is a 9.5mm High Tact Switch by Radio Shack, part number 275-0003. Comes in a pack of 4 for a few dollars--give one a try and let me know how you make out---Sun

I bought those, but haven't used them yet because the wiring diagram is sketchy and cryptic. It has me unsure how to wire it. I have been using the mini pushbutton switch, also from RS (part number 275-1547).