I see all kinds of people asking for a #20 switch mod. I completely reworked my switch a bit over a month ago and it is still going strong. My #20 now has an adjustable brass center center pin, and does not require a weird (and potentially weldable) spring to make contact.
Keep in mind that this mod is not perfect. I occasionally have misfires (probably about one out of every 10 times I hit the switch). However, the following modification has eased my mind about the possibility of a welded switch, and also hits a hell of a lot harder than the stock switch. As usual, any attempt to follow this modification is at your own risk - I don't warrant or otherwise guarantee that this will work for you or that it will be safe for you. YMMV. You also risk completely destroying the switch if you undertake this modification, rendering your mod completely useless.
Disclaimer over. I ordered some 3/16" brass rod off of amazon. This brass rod is the central part of the modification to the switch.
The first part of the mod is to completely disassemble your switch head. There are plenty of other tutorials around for this, so I'm not going to repeat them.
I started by cutting about a 4" piece of the rod for the top post. Then I carefully drilled and tapped about a 1" long hole in the center of the rod along its axis. A drill press and a good drill press vice are incredibly helpful in centering and drilling the hole. The tapped hole should accept either an 8-32 screw or a 6-32 screw. I then cut this entire drilled and tapped portion off of the remaining rod. Keep in mind that it is helpful to have a bit too much drilled and tapped portion of the rod. You will need a proper size and pitch set screw to serve as the adjustable top pin. Preferably this screw would be solid brass. I ended up making my own because the only brass set screws I could find were terribly expensive. To make your own, just get a longer machine screw, cut it off, and cut a slot in the cut off end to accept a flat blade screwdriver.
You'll also want to cut a short length of brass rod (about 1" long, and not drilled or tapped) to serve as the bottom post.
The final preparatory step for the top and bottom brass posts is to sand or file a slight bevel onto the edge of the post. This is where the button will make contact with the posts. You'll want this bevel to match the bevel on the contact side of the button as close as possible to have the most surface area for contact.
The next step is by far the most difficult part of the process - this is to set the brass rods in the delrin switch housing at the proper depth so that the button can bridge the gap between the posts and make good contact, without having the brass posts actually touch each other. You'll first need to drill out the post holes in the delrin to accept your 3/16" brass rod. Then you need to set the depth of the brass rods. How I did this was I inserted the brass rods (threaded one at the top) into the delrin switch housing and then inserted the assembled button housing into the delrin switch housing. I then pushed the button, and fiddled with the bottom post until it felt like I had good contact between the switch and the bottom post. You can check this by placing a multimeter across the button and the bottom post to check for continuity. Repeat the process with the top post. Once you are sure that your top and bottom posts are placed perfectly, check the continuity across the top and bottom posts with the button pressed (should show no more than about 0.2 ohms of resistance) and with the button open (should be no continuity). Once you are absolutely sure that your brass rods are ideally placed, use some superglue or epoxy to set the brass rods in the delrin switch housing. Check continuity again here. Pull the button housing back out at this point used some more superglue or epoxy on the inside to further set the brass rods in place.
I also mechanically set the bottom brass rod in place by drilling straight through the delrin housing and the bottom brass rod and inserting a proper size roll pin. The bottom pin will generally have much more pressure exerted on it than the top pin. On the top pin, I relied exclusively on glue to hold it in place. You could possibly use some sort of set screw to hold the top pin in place though.
The next step is to cut/sand the protruding brass rods to the proper length. I used sand paper and hand sanded them to the right length. This took quite a bit of patience. I sanded the top rod flush with the delrin housing. The bottom pin I sanded to the point where it protrudes about 1/8" from the housing. Be careful not to build too much heat here - you could potentially melt the delrin housing.
Finally, test continuty again, and assuming all is well, reassemble the switch head and vape your head off. Here are some pics of the modifications:
Other modifications that I've done to the #20 include sanding the top brass insert so that attys will sit flush, replaced the bottom spring with a brass screw (be careful with this as we're talking about the removal of this device's sole safety feature), and replaced the interior delrin washer with an o-ring to seal the atomizer connection area. Keep in mind that with any modification, you are potentially taking your life into your hands. Be sure that you know what you are doing and the potential risks entailed before you start.
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