Just rebuilt my first protank coil!

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gisforgirard

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Nov 26, 2013
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SE Michigan
I've been researching online for over a week on how to rebuild protank coils while I wait for my replacement ones to come in...

On black friday I noticed an e-cig shop (esvapes) that I have drove past easily thousands of times and never noticed it was there, so I had test some new flavors out while I was there, and black friday prices 3.70 out the door for 10ml bottles, score!

Anyway, while I was browsing their shelves I noticed they had some kanthal wire (28 gauge) which I haven't been able to find locally, so I picked some up on a whim. After some more research, it turns out 28 gauge probably wasn't the best selection in retrospect, but whatever I already have it now I'll make it work. I'm sitting here bored on saturday so I decided to take the plunge and just try it out.

Already had the old one pulled apart, so I just cut probably 6 inches of wire to wrap my coil. Grabbed a 1/16" screwdriver bit, and started wrapping. Every wrap I push it close as I can to the last one. Get about 8 wraps done and try to test fit it, pretty big and it might touch the sides. I put it back on the drill bit, carefully unwrapped one wind and straightened out the wire, then got the needle nose pliers and scrunched the coil together as much as I could.

Test fit again, looks good, so I put it all back together using the good coil I have left as a reference, screw it into the base, and grab the multimeter. Testing the resistance, looks like about 1.0-1.1, pretty low but I read it tends to rise once you get some juice on it and break it in a bit. Before I put in the cotton I do a dry burn just to test that it works. Coil's glowing real nice, everything is looking good so far! I'm excited! I thought this was going to be way harder!

So now I take some cotton and put it in the middle of the coil, looks good, get out some juice and wet it down a little, take a little bit more and put it on top as a flavor wick, wet that down the same way too. Put the top on, screwed it into the tank, and let it sit for a minute. Took a hit -- WOAH! This is nothing like the old coil!

I'm definitely getting way more vapor production and everything works so I take off the tank, put it on the multimeter again. Now that I've got it all together it's up to 1.3-1.4, getting closer to the target, so I put it back together and hit it a few more times. Kind of a weird flavor at first, but it's going away the longer I let it sit and take a few hits at a time. The resistance is now up to 1.4-1.5, which is almost perfect :)

I'm assuming it's normal for there to be some weird flavor at first, but does this go away with time? It's going away the longer it's been but there's still some strange burning flavor. I took off the top flavor wick and thought it was burning, but rinsing it with water gets it perfectly white again, so not sure what's actually happening here.

Can't wait to try some other wick material next, hemp or bamboo. I've seen people getting aunt lydia's bamboo crochet thread and some other brands for hemp at michaels or joanns and boil it and it works fine.
 

Dakota Jim

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Yes, cotton has a weird taste to start with for me also (organic, unbleached cotton) so I prefer silica (how can anything that has grown from the ground for thousands of years be better for you than something that has been manufactured? I also won't eat anything without preservatives. What's going to keep me alive and fresh?)

as for wire I use A1 30 ga - 8 wraps on a 3/48 machine screw and then torch it red and squeeze coils with needle nose pliers while still red until all coils are touching but not overlapping. Narrow enough to fit and big around enough to thread cotton or a doubled over 2mm silica wick - end up with a consistant 1.9 ohm protank coil
 

danny4x4

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8 wraps of 28awg on 1/16 bit should nett you about 1ohm. So you're about on the spot the first time. The increase to 1.5 ohms worries me. It shouldn't be doing that.

Fire it up again and immediately after, check the resistance. It would probably read 1ohm again. I've found that bcc clearos with removeable heads tends to have this problem when paired with certain heads. Swap the heads and the resistance stays constant.
 

gisforgirard

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Nov 26, 2013
19
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SE Michigan
Try 30g, it'll give you higher resistance with less wraps and have no problems fitting it in the kanger cup. Burnt flavor might be from the rubber insulators. They sometimes burn with lower resistance coils.

Yeah, I was worried about the resistance off rip. I saw kanthal wire and bought it without even thinking to look at what gauge it was, so I ended up with 10ft of 28awg that I was working with... might be the rubber though, even though I tried to get it as close to the middle as possible. Just re-wicked it and not having the same problem yet, so it might just have been a rookie mistake where I got impatient and heated it too much before everything wicked up real good.

I did pre-wrap another coil with 9 wraps so I might swap that one for the one I have now soon, to see if the extra wrap is worth it or I should jump straight to another gauge wire ASAP
 

gisforgirard

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Nov 26, 2013
19
1
SE Michigan
8 wraps of 28awg on 1/16 bit should nett you about 1ohm. So you're about on the spot the first time. The increase to 1.5 ohms worries me. It shouldn't be doing that.

Fire it up again and immediately after, check the resistance. It would probably read 1ohm again. I've found that bcc clearos with removeable heads tends to have this problem when paired with certain heads. Swap the heads and the resistance stays constant.

Honestly, I can't explain this either. Might be the added resistance because I'm checking it with the base connected & touching the center pole and the threads with the multimeter, it's a fluke 87 multimeter (good kind, dad's an electrician) and I've got the same reading multiple times. When I originally got the 1.0-1.1 reading it was without the base connected (coil only) so that might be part of the discrepancy.
 

gisforgirard

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Nov 26, 2013
19
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SE Michigan
It's cotton from a Q-tip so that might have something to do with it. Re-wicked it a while ago and haven't had the same issue since so it might have been from the wick burning or maybe it was like another said, the rubber seals, because I did have to re-position the coil a bit in the process of re-wicking it. Hopefully I can find some bamboo to try next :)
 

gisforgirard

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Nov 26, 2013
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SE Michigan
The more I hit this rebuilt 1.4/1.5ohm cotton wick the more I realize I was holding down the button a lot longer with 2+ ohm stock coils to get the same amount of vapor.

Now with a 1 second burst I get more vapor than I was getting before with 4-5 second hits. I think I was so used to the old style that I was burning the wick without even realizing it!

Even with the huge air flow of the base on the mini protank 2 v1 it has plenty of vapor with a super short draw. This is something that is taking getting used to, as I think I was burning the wick unintentionally. I can't wait to try some other wick materials and see if they hold up better :)
 

gisforgirard

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Nov 26, 2013
19
1
SE Michigan
Bought some 32awg wire and 2mm silica wick over the weekend, esvape just stocked it so I had to try...

Immediately I realized I'm not fitting this wick into a pre wrapped coil. I tried anyway, it frilled everywhere, didn't make it even halfway into the coil, I threw everything away and started again. So I end up taking a sewing needle and holding it tight against the 2mm silica wick, which is like 2 inches long at this point because it was too frustrating to work with anything shorter, I can cut it when I get done anyway.

Wrapped a piece of 2mm silica w/ 4/5 wraps, ended up @ 1.5 ohm, burned the rubber grommet again. ...., try it again when I'm not drunk.

Wake up, realize the coil sucks and try again. End up doing the same thing, same resistance, same result. ...., okay third time's a charm.

Wrapped it 6/7 times and end up getting a 2.2 ohm coil. Perfect. It performs great, wicks great with 70% VG juice, and doesn't burn the grommet like the first two.

32awg is way harder to work with than 28, it wants to bend more and I would love to try 30awg wire if I could get my hands on some. Maybe I'll try some flat wire next, who knows?
 

devauto

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Mar 13, 2013
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Okay, so my guess is that your weird flavor is coming from the bottom grommet. I have been told by my local shop that 28g Kanthal heats up too fast and causes the grommet to burn or melt. As you hit it, the flavor of the burning grommet gets sucked up through the air flow (as designed) and mixes with the flavor of the vapor. Ultimately, the grommet burning or melting will keep you from reusing that head unless you can find replacement grommets.

HTH
 
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