DIY - AA 3.6v Battery Case

[opusMorian]

Here is another mod. The screwdriver mod I promised will have to be delayed since DealExtreme messed up my order again. After 1 1/2 months of waiting, they sent me the wrong item. Awesome!

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!


Difficulty = 3 out of 5

Parts list:
DealExtreme: $5.75 Cell Phone Emergency Charger (1xAA) - Emergency Cell Phone Charger
DealExtreme: $5.71 Universal Smart Quick Charger - Recharges All Batteries (100~240V AC) - Charger for the 3.6v (4.2 charged) battery
DealExtreme: $3.99 TrustFire 14500 3.7V 900mAh Rechargeable Lithium Batteries (2-Pack) - AA Size 14500 3.6v battery
Radio Shack .... Connectors Part# 64-3036
9.5mm High Tact Switch from Radio Shack part# 275-0003
Size N Coaxial DC Power Jack with Switch part# 274-1583
30 gauge wires
Retaining Ring External 9/16" 14 3 Plain Steel part# 030699395482 from Home Depot

Tools you will need:
Solder gun
Solder
Disposable Filer
Drill
1/8 Drill Bit
5/16 Drill Bit
Patience


Lets start!
Here is what the Emergency battery charger from dealextreme looks like from the left to right, the battery charger, a AA battery and a cr123A battery:


It comes with a DC step up circuit. The circuit will boost the 3.6v to a 6.4v. Too bad there is not enough current (amp) that goes with that step-up. Its basically useless for our application (will not power the atomizer. Will be useful for a led flash light though.




First lets prepare the retainer ring. This ring will sit in the same place the above circuit was. It will help make a good ground connection once we screw on the clear plastic cap.



We are going to file both side of the retainer ring so we can get a better contact and also allows us to solder a wire to it. We are going to cut a 1 3/4 inch of 34 gauge wire and solder one end of it to the ring.


Now we are going to prepare the tact switch and the Size N Power Jack.
We are going file a small part of the power jack so we can solder to it. We are also going to cut off the two pin on the side and then fold the center pin towards the middle. This will act as out positive contact for the battery once we install it.


Now cut another 34 gauge wire about 1 3/4 inches and solder it to the part of the power jack we filed.



We are going to take the 22-18 (the bigger one) .... Connectors and cut it in half. Insert the .... connector into the center of the dc power jack to boost up the height of the center pole.


Now solder the other end of the wire to the tact switch.

 

[radiokaos]

Bloody awesome instructions and pic's.

 

[opusMorian]

Take the retainer ring that we prepared and solder the other end of the wire to the switch also.





Let prepare the clear plastic cap. Use the 1/8 drill bit to drill a hole on the side. The center of the hole is 8mm from the top. You want to make the hole a little bigger so the plastic button on the tact switch won't get stuck.


Use the 5/16 drill bit and make a hole on the top of the cap. With the hole you just drilled for the tact switch at the 12 o'clock position, the center of the hole is 11.3mm from the top.




Now we are going to work on assembling these parts. First we want to tape the dc power jack so there are no chance of making contact with the switch.



First fit the button in the side hole, then fit the dc power jack into the top hole. Use the nut that came with the dc power jack to secure it to the cap. You might want to file the nut down on both side so we will have more thread to screw the atomizer on. I end up having only about 3 lines of thread, but I am sure if I filed the nut more I can get more thread out of the power jack.




Fold a small piece of tape (4 folds) and put it on top of the tact switch before you put the retainer ring in. The tape will help push the button up against the retainer ring so it won't move down.



The we want to place the ring inside after everything has been fitted in. It should fit perfectly where the Dc step circuit used to sit. I would rotate the ring to make sure it has enough distance from the center pole. We don't want make a short.


We now screw the cap back onto the aluminum center. Use a multimeter and make sure that a connection is made when you press the button.

After that, plug in your battery and make sure you are getting 3.6-4.2v when you click the switch.

BAM! You are done!



The atomizer will be slightly angled. This position is pretty comfortable.

Let me know if anyone have any question. Have fun ..

 

[opusMorian]

Bloody awesome instructions and pic's.

Thanks!

Wow you are quick. Caught me in the middle of the post .

 

[franklyspeaking]

I see you cut the two end posts on the Size N Coaxial DC Power Jack with Switch. One of them would be the negative post, what's the other? This piece could be used on a magnum style mod as well, right? All that would need to be done is to solder the negative and positive to the right posts...right? or am I missing something. It looks like this would be much better than dealing with killing a battery. Looks much easier to mount as well since it screws down.

Great mod and instruction BTW!!!

 

[2kool2]

Nice work !

 

[opusMorian]

I see you cut the two end posts on the Size N Coaxial DC Power Jack with Switch. One of them would be the negative post, what's the other? This piece could be used on a magnum style mod as well, right? All that would need to be done is to solder the negative and positive to the right posts...right? or am I missing something. It looks like this would be much better than dealing with killing a battery. Looks much easier to mount as well since it screws down.

Great mod and instruction BTW!!!

Thanks! One of the pin is negative, the other one is a engage pin. Inside the core of the center pole, there is a metal contact that is normally open. When you insert a male connector that suppose to fit in, it pushes it outwards and makes contact with the negative pin. Its not used in our application, so we just cut it.

 

[franklyspeaking]

OK, makes sense now. Thanks. So it seems I just need to copy what you have done and it should work nicely in a magnum type mod. Awesome, thanks so much for such detailed instructions and your reply!!

 

[ceo51378]

Very nice mod! I love it! Being that you have that transparent cap, you could spray the inside of it with that 'frost' spray paint, then throw an LED inside to pimp it out a little.

 

[radiokaos]

Very nice mod! I love it! Being that you have that transparent cap, you could spray the inside of it with that 'frost' spray paint, then throw an LED inside to pimp it out a little.

I like the LED....HOWEVER, I think you should leave the cap clear. Thats the coolness factor. Its nice to see the work and button.

 

[Vape]

Size N Coaxial DC Power Jack with Switch part# 274-1583

Are you able to use a 901 atomizer on this or does that work with the 801/penstyle atomizer?
Sorry, I just couldnt tell in the pictures.
Very cool stuff, thanks for sharing!

 

[nicowolf]

Size N Coaxial DC Power Jack with Switch part# 274-1583

Are you able to use a 901 atomizer on this or does that work with the 801/penstyle atomizer?
Sorry, I just couldnt tell in the pictures.
Very cool stuff, thanks for sharing!

That works for the 901, but not for the penstyle. The penstyle equivalent is a modified audio jack.

 

[opusMorian]

Size N Coaxial DC Power Jack with Switch part# 274-1583

Are you able to use a 901 atomizer on this or does that work with the 801/penstyle atomizer?
Sorry, I just couldnt tell in the pictures.
Very cool stuff, thanks for sharing!

nicowolf is refering to this thread:

http://www.e-cigarette-forum.com/fo...o-battery-sacrifice-adapter-801-penstyle.html

I don't have a 801 yet. i have seen that at radio shack and it look pretty big. It might fit with some modification into this mod but not sure. Might ask nicowolf if he has any hint on working with the 801 adapter.

 

[Vape]

nicowolf is refering to this thread:

http://www.e-cigarette-forum.com/fo...o-battery-sacrifice-adapter-801-penstyle.html

I don't have a 801 yet. i have seen that at radio shack and it look pretty big. It might fit with some modification into this mod but not sure. Might ask nicowolf if he has any hint on working with the 801 adapter.

All I have atm are 901's. So that's actually exactly what I want!
I was just at Radio Shack today getting goodies, wish I read this before I went!
Thanks so much

 

[zip]

How is the vapor production and how long does the battery last?

 

[opusMorian]

How is the vapor production and how long does the battery last?

With the same 7 second puff as the regular 901 battery, there are thicker smoke. The battery last me about 1 1/2 day while the dse 901 battery last me about 4 hours with my smoking habits.

 

[opusMorian]

Just wanted to do an update since I am coming close to two weeks usage.


Pros:
-The smoke production is more then my prototype screwdriver
-Heats quicker then the screwdriver due to the direct contact from the positive side of the battery to the atomizer
-Last about 2 hours more then the screwdriver (screwdriver was 3.6v at 880mah)
-Charging is about 30mins to 60mins shorter then the screw driver (screwdriver was 3.6v at 880mah)
-Easier to hold and use then the screwdriver since the button is near the top
-Last much much much longer then a OEM 901 bettery (around 2-3 hours on average)
-Produce much more smoke then the OEM 901 battery
-Manual switch so you smoke as long as you want (probably don't want to hold it more then 10 second to be safe)


Con:
-Bigger then the OEM battery and a tad fatter then the screwdriver

 

[kender]

Very nice opus!

 

[opusMorian]

Thanks! I am think about making like 10-20 of these and sell them as a complete kit to get more funds for equipments like a drill press/lather etc. The new equipment can help me product my mods easier and probably improve the quality of my step-by-step guides. Would you guys be interested? thinking about selling these for like $45 shipped in the US. Just a thought.

 

[mysticalman]

Thanks for the write up. I am going to try to modify your mod to work with my 801.

I was fortunate to have a DOA battery right out of the box so vaping with 1 battery kind of sucks, and I am just to cheap to pay for shipping to get the replacement out of china so this should be perfect!