Just recently started happening, I punch my own boge LR cartos...2 holes at the base. Slide up into tank, remove fill screw and use needle tip to fill. Only suddenly i'm getting a lot of resistance when squeezing the juice in, and then juice will flood the carto and leak out the battery connector. Only happens when tank is about half full.
I'm not sure whats causing this, seems like air pressure would be the culprit but when I remove the screw that should even it out right?
There are a few things that can cause a cartotank to leak. If you are certain that the leaking is coming from the air hole in the battery connection, it probably is the cartomizer that is flooded.
Some newbies attempt to fill their cartotank with the top cap off. When they attach the top cap, there is such an increase of air/liquid pressure built up inside the tank it forces too much liquid into the carto, and it floods and leaks. This scenario does not seem to apply to your situation, but it could.
By filling the tank via the juice feed hole, you are in effect increasing the pressure inside of the tank the same as what I described above. The air in the tank must be allowed to leave the tank while filling it with liquid. I assume that you are filling with a needle and syringe? You may need to withdraw some air periodically while filling. Add some liquid, withdraw some air, add more liquid, withdraw more air.
Another possibility is that two holes are too many for the particular juice that you are using. For a standard 50/50 pg/vg ratio I get great results with just one hole of the tiny laser-drilled cartos. Anything with more vg in the ratio, I use the two hole laser-drilled. You may possibly be self-punching your holes too deep and puncturing the inner air tube, allowing juice to escape.
Are you drawing too hard on the cartotank? Despite the number of holes in the carto, sometimes a carto has a hard time keeping up with the juice demand if you are inhaling too hard or frequent. Slower, steady draws work best with a cartotank.
I can't say for certain if the above things apply to your situation, but I thought I'd give you some benefit to my own experience with cartotanks. Good luck.