Need help repairing/rewiring a Bolt

[dlbald]

I got a Bolt as a PIF so no warranty. When I first got it it worked only intermittently and then quit completely. I read up on it and found out it was a common problem because of the small wire and it was a relatively easy fix by replacing the wiring. I used 22 gauge solid (unstranded) wire and made sure the button was working before putting it together. I did check the grommet at the connector and it had torn so I replaced it. I took a few puffs and all was good so I went ahead and hot glued the innards in place.

After just a few more puffs it quit completely again. I took it all apart and before repairing again I retested the button. Now the button is dead. I ordered 2 more buttons like the one it came with (the black horn button from Mad Vapes). I put it back together with the new button and it worked and died again and button is dead again. I did not hot glue it that time. Got some new wire, 22 gauge stranded, and put it together again and tested again. Now I notice that the tube is a lot warmer than I felt before after 4 or 5 puffs. I took the battery out and it is warm, not hot. I waited a little while, put the battery back in and took a few more puffs. Getting warm again. I do not want to use it at this point.

At this point the button still seems good, the grommet appears to be seated right, the solder joints look fine, spring looks fine.
The battery is a smok icr18500 1500mah charged to 4.10 volts.

Any thoughts and suggestions will be appreciated.

 

[dlbald]

If I have to get another button, which one would fit the best?

 

[bapgood]

I'm amazed you got solid wire back in there...I wonder if it is your problem. Either pushing on the switch in some way to cause it go out, or where it's getting warm possibly grounding out somewhere. I would suggest using standed wire and checking the solder joints. It's been a long time since I fixed mine, but I remember just using heavier stranded wire and getting good solder joints. After I fixed it I used it hard for over a year as my only PV and still use it occasionally with the original switch.

Edit.....guess I should read closer

 

[dlbald]

I had read conflicting ideas regarding solid and stranded wire. The stranded definitely is easier to manage inside the tube.

 

[darkpoet]

I know this is an old thread but I have two Bolts and I love them. Yes, the madvapes switch will work... these are the same: 2pc Black Momentary Off on Push Button Horn Switch B170 | eBay (the same seller has other colors, too). I used hot water to pull the glue apart (scalding water will do)... and the inside of an old LAN cable to replace the crappy looking stranded wires. LAN innards are stranded but thick copper. I forget which video it was on Youtube but the guy said shorter wires are always better and flux is your best friend when fast soldering (the switches can easily melt)... My newly wired Bolt seems to hit harder than the other. Makes sense, too since the old wires are longer and lower-quality (ie. higher resistance).

But I'm wondering if your battery is a problem. I only use 18650 protected batteries in mine. Also, are you using the extension with the 18500? The spring might get pretty squished if you're not...? The spring will turn greyish and shrink if there's a short circuit... but it will still conduct. Not sure where you can get replacements (I'm in Korea) but I wouldn't use my Bolt without a good hot spring.