Simple box mod with "swappable" resistors

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mars_mcc

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Jun 14, 2009
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I thought this might be helpful to some folks.

I wanted to figure out a way to try different resistors to find out what voltage I ultimately wanted to use with my 901 atomizers, so I got a bunch of different resistors and soldered in 2 "clips" using earring backs to hold them in place. So now I can swap the resistors out fairly easily and am still able to take the box out with me to try out each variation for a couple of days at a time of normal vaping.

It's a basic box mod (nicostick), with a 3 AA battery box (with built in switch), with the standard "nicostick" style radio shack pushbutton switch and an OEM 901 connector (thanks to Nerf). The batteries are 2 protected 3.6v 14500 Ultrafires (again, standard nicostick, but doubled). Fully charged they put out about 8 volts together, obviously WAY too high, for me anyway.

I've tried a few different resistors now, but so far I think I get the best results using a 2ohm 2watt resistor, which brings it down to about 4.75 with fully charged batteries. Any higher and the vapor starts to taste noticeably burnt (IMO anyway). (If people want that, then just use a smaller/lower resistor, of course, everyone is different)

The resistor heats up a bit, but cools right back down, and I've kept it as far away from the batteries as a could in such a little box, to be as safe as possible. (The atomizer seems to heat up quite a bit well before the resistor gets hot enough to melt anything, at least that's been my experience so far... so I let it cool at that point anyway)
I've also added as much heat shrink tubing as I could get in there, to try to avoid shorts and to give it a cleaner look.

I know that this is wasteful as far as the battery power goes, but all I have to work with right now are AA boxes and 14500 batteries (until I get more stuff anyway), and IMHO it is worth it to get a much more satisfying vape!

This is not a permanent solution, I don't think, for me anyway. Once I find out exactly where I want the voltage I will probably just solder and epoxy it all together like a normal box mod, or even better yet use a 5v voltage regulator, and bring it down a little bit from there maybe, I'm not sure yet.

I hope this helps others in some small way, as I have received a ton of help from all of you and your great informative posts!

Oh, and thanks to Cashmere for helping me find the resistors, and Nicowolf for her great directions and pictures!
 

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kinabaloo

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Wonder if it might be worthwhile using that wasted power by placing the resistor in the air path using some metal tubing, taking care re possible shorting. Not really something can quickly do; more a thought that might lead to something in the future.

Otherwise, if resistor getting hot is a problem, use a larger one, though 2W is already quite big. One could glue some aluminium as a heat shield along the center too; just an idea.

Personally, I think 1 14500 is enough, but i also know many like to go a bit higher ;)
 
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mars_mcc

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Jun 14, 2009
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Maine, USA
Here's the same 3AA box as above (with the resistor 'clips'), with a 3mm LED with 100ohm 1/4 watt resistor added also.

The LED fits perfectly in the hole that the case came with, and it's flush with the case too. Also, this keeps the LED and resistor away from the big resistor up near the atomizer (the one that gets a little hot).
 

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mnealtx

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Jun 16, 2009
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Wonder if it might be worthwhile using that wasted power by placing the resistor in the air path using some metal tubing, taking care re possible shorting.

That's an interesting thought, kina - with some of the comments I've seen about 'cool vapor', I wonder if that would work as sort of a 'pre-heat' for the airstream?
 

kinabaloo

Vaping Master
ECF Veteran
Perhaps... of course, it all depends on just HOW hot that resistor is getting...but still, putting in the airflow in some way should help keep it cool - thermal cycles might become an issue, though.

I doubt it would affect the air flow at all. It's say 2w with the coil running at 5w so it should certainly help. Guide the airflow with some piping and have the resistor inside on connecting wires.
 

mnealtx

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Jun 16, 2009
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Camp Bondsteel, Kosovo
I doubt it would affect the air flow at all. It's say 2w with the coil running at 5w so it should certainly help. Guide the airflow with some piping and have the resistor inside on connecting wires.

Running at 2.5x the power rating SHOULD make it nice and toasty...and would hopefully warm up the vapor for the 801/901 folks that say it's too cool.
 
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