Need some tips on AA battery box construction

[b00stzx3]

Hey all. Have made about 6 510 AA battery boxes (from madvapes) now. Had some construction issues that I was looking for tips on. I'm using JB Qik-weld as Epoxy for everything. Sometimes even after its dried though, the button or the connector seperates or becomes loose from the box. How is everyone doing this with the epoxy? I worry about getting epoxy on the connector threads when pushing it ino the box. And the button, having trouble keeping excess epoxy squeezing out when the buttons pushed in and also making it sit flush/flat on the box. Also, anyone recommend different batteries than the trustfire/ultrafires they sell at madvapes? I've seen the AW's, and if they're worth the extra $6 or so performance-wise over the Ultra/trustfires I'd get them.

 

[Java_Az]

You can use acetone to clean the area before applying the epoxy. It will cut into most plastics , by cut i mean it will melt the plastic a bit. You should get better adhesion by doing that. I dont think it will be full proof but might help the bond last longer.

AW's are for sure worth the extra cash. Maybe not for the added performance but for sure worth it for not lieing to me on the spec sheets. True Mah tests have proven over and over the ultras and fires are overrated. But even if you adjust dollar per mah the cheaper china batteries are still a better value. But i refuse to support companies that are going to lie to me about there products. If they ever decide to put true mah ratings on there batteries i might reconsider. For now i will only buy Japan or Korean made batteries.

 

[Erwin]

Which switch are you using for your 2XAA boxes? If you are using the horn style switch here is a suggestion. Take the nut and grind down two of the sides opposite of each other. This way you can still use the nut to secure the switch and eliminate the need for epoxy. Has worked very well for me so far. If you don't grind down the sides of that nut it isn't going to sit flush in the box without making the sides bulge.

 

[warbdan]

Yep, that's what I did on my nicostick. Works great.

 

[sgtdisturbed47]

I use Hot Glue instead of Epoxy.

 

[hiram13pm]

I start with a very small amount of epoxy, just enough to secure components in place, and let it set completely. If placement isn't right, it's easy enough to break it out and start over. Then I mix a second batch of epoxy and really lather it on to cement it all in. Haven't had any issues like yours since. My first box ran into epoxy in all the wrong places, I think, because I tried to do it all at once.

 

[b00stzx3]

Thanks all!!

Acetone to pre-clean seems awesome. Make it bond better, or I might try Hot Glue like above. I'm using Madvapes Horn-styles, will try to grind the sides thats a cool idea. Didn't even think of that!! Before I just took the nut/washer off completley so just the bare threaded plastic. Also love Hiram's idea.

Thanks all!! Gonna order an AW as well.