Being an engineer, owning a ProVari and several ProTank-II's and a couple ProTank 3's, and exhausted searching the forums for the right answer, I tore everything apart, measured everything with a micrometer, and performed various tests to find answers to all the problems.
Not sure exactly how the ProVari could cause a protank to leak
If you don't screw the atomizer into the base tight enough, the pressure from the positive post in the ProVari pushes the atomizer up enough to cause major leaks in some cases. The alternative is to not screw the tank to the ProVari very tightly, which tends to start coming loose often, besides looking funny with a gap inbetween.
best fix I've seen is this: get an Aerotank base for your Protank
Actually, that's the worst "fix", again unless you don't mind a huge gap between your tank and ProVari. I got a couple AeroTank bases, and have done quite a bit of modification to get everything the way I like.
Also the Aerotank base is sealed so it doesn't leak on your Provari
That's another half-truth. The positive pin on the AeroTank base IS sealed and won't leak onto your battery. However, the atomizer still leaks, and guess where it goes? Into the AeroTank base, where it'll cause a noticeable voltage drop, just like your ProVari positive post filling up with liquid. Same thing, different place.
I love my protank just doesnt seem to work well with the provari for some reason.
Yep - just about everyone experiences that. Here are some causes and solutions. I like an airy draw - some people like it tighter - to each their own. When you screw a ProTank onto a ProVari, the draw gets tighter (and sometimes closes off the airflow completely). The reason for this is the rubber insulator on the positive post of the ProTank gets compressed, bulges outward, and blocks the airway. There are two solutions for this, and I do them both. 1) Using a metal file, reduce the bottom of the positive post of the atomizer. Be careful not to take too much metal off, or there won't be a path for airflow. 2) Push the bare atomizer down on a hard surface so you see the rubber bulge. Use fingernail clippers multiple times around the insulator, so that when you release pressure, the insulator is concave. Now when you screw it onto your ProVari, the insulator bulges, but only to the edge of the post and not blocking the airway.
Since I like more airflow, I also drilled the 3 air holes in the post of the tank to 1/16th". For me, those two methods have achieved perfection, to my liking. I also recently experimented with the AeroTank base. Oh no, even more trouble. Like I mentioned above, the base does not leak, but it fills up with juice just like your ProVari used to. Not only that, but the gap issue is much worse. Without really tightening the AeroTank base onto the ProVari, there is a 0.75mm gap, which looks really bad. Gaps really bother me, so I had to solve this too.
I used a large round piece of metal to push the positive post out the bottom of the base. The insulator comes out with it, and is very difficult to get back into the base without tearing it, so be gentle, take your time, and you'll get it back in. Then take a coarse metal file and file 0.75mm off the TOP of the positive post. The post measures 6.03mm, so you'll need to get it down to 5.28mm (I got mine down to 5.29mm, and it fits perfectly on the ProVari now). When you're getting close to 5.28mm, switch to a fine metal file to smooth out the post. I used a pair of pliers to hold the post while filing, which greatly helps keep it straight so you don't wind up with a wedge shape (not good for electrical contact). I also drilled the 3 air holes in the AeroTank base to 1/16th" - the difference is I can tighten the draw if I want, or open it all the way up.
To further complicate things, I'm also using the Davide BCC to BDC adapter with the Aspire dual-coil heads. It's a frankentank, but I finally got it where I want it. Feel free to PM me if you want any help with any modifications you decide to try. Good luck!
