The Big Chuck is 5" long, the Little Chuck (which only vapes 3.7v) is 3.5" long. I have both. I'd say the diameter is about the same as a roll of quarters - just a shade smaller.
I MOSTLY vape 3.7 volts on both and sometime 6v on the Big Chuck. I find the 3.7 v satisfying all day long - if I vape 6v, it gets a little too hot and harshe for me in less than an hour (this is with a 901 adapter - I haven't yet gotten the adapters I've ordered to try an 801 atomizer, and I've heard many people say that's the best atomizer for 6v
vaping.)
I've also heard from some people that a Chuck at 3.7 beats out a Silver Bullet at 5v, but I have no experience with the SB.
You choose your 'decoration' of your Chuck. Many of the ones I've seen are a solid powder coat over the copper body, then possibly some decals of designs, then a clear coat over that. You can also choose an 'illusion' color for the clear coat, making the Chuck shine with colored specks. One of mine is amethyst, and depending on the light, you'll see green sparklies or red sparklies. I just got another aquamarine illusion where the main 'sparklies' depending on the light seem to be blue and green. (That one has a gorgeous silver filligree decal rising up the body of the Chuck).
As far as I can tell, it would be difficult to damage the finish on a Chuck. One Chuck-owner left the Chuck on top of the car before driving away, driving OVER the Chuck in the driveway - this damaged the switch but the owner didn't say anything about damage to the finish. Jeff repaird the Chuck under warranty, btw.
Another person who had been used to flipping cigarette butts out the car window did the same with his Chuck in the highway - had to turn around to go search for it. I don't recall him saying it damaged the Chuck in any way (but if it did, I'm sure Jeff fixed it.)
I have another
mod with a painted aluminum body that I've only had for a few weeks, and there are spots where the paint has flaked off in places that don't even come into contact with my hand - there's no second coating over the paint job; that same mod also comes in colors that are just a vinyl wrap on the body - sounds to me like the finish would be something like a dime-store do it yourself project with Contact paper.
Another mod I have just has an aluminum body and I don't know what, if anything, the body is covered by. I haven't had it long enough to tell if it will discolor from contact with the skin and oils of my hand.
My oldest Chuck is two months old and maybe at SOME point I'll want to get some Brasso to polish up the brass end caps, but the Brasso hasn't made it to my shopping list yet.
If you haven't done so yet, take a look at Thagbuilt.com and see some of the great samples of Chucks that Jeff has made already.
BTW, you can consider yourself a Chucklehead before you even order a Chuck - it's the thought that counts.
