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0WalkThrough
Notice:Thisguideispublishedasopensource.Iwelcomeallsuggestionsandhavetriedto
makeitaseasyaspossibletofollowsothatanyonewhowantstobuildonecandoso.
Pleasedonotusethiswalkthroughtomakethemodforprofitandhelpencouragethe
opennatureofthemoddingcommunity.
Forquestionsandsuggestionsvisit
http://vapersforum.com
andsendamessagetoNuck
Name
Fistpackv2.0(variablepower)
Batteries
18650AW2600mahORAWLiMN1600mah
(lowermah,veryhighdischarge,safe
chemistry)
Power
Variable(4.35,4.60,4.75,4.95vunderload)
Atomizer
Variable(thisguideusesa901,switchingto
an18500batteryallowsuseofa510)
BuildTime
35hours
Costofcomponents
Approx6065bucks
Disclaimer:Thismodcanbeveryfrustratingtobuild.Spaceistightandthereisalotof
roomforerror.Youshouldhaveatleastafewmodsunderyourbeltoryouregoingtoend
upwastingyourmoney.Onthebrightside,Ihaveaveryweakbackgroundinelectronics
andmysolderingskillsaremediocreatbestandI'vemanagedtomakealotofthesemods
successfully.Justtakeyourtimeandtakeitonestepatatimeanditwillallfallintoplace.
Credit:TherehavebeenmanypeoplethathavehelpedoutalongthewaybutI'dliketo
specificallymentionRjGasbeingincrediblyhelpful.Hehashelpedmetrackdownerrorsand
pointedoutweakareaswithsolutionsmoretimesthanIcancount.ThanksRandy:)
Parts
Fistpackbody:
(Blue)
http://www.dealextreme.com/details.dx/sku.23734
(Black)
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWNX:IT&item=220
402222514
Switch:
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=GH1349ND
SwitchCap
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=3602162ND&itemSeq
=83081762&uq=634024529165533812
SlideSwitch:
http://search.digikey.com/scripts/DkSearch/dksus.dll?WT.z_header=search_go&lang=en&si
te=ca&keywords=6791874ND&x=22&y=15
Capacitors(2required)
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=49515291ND
Diode
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=B280FDICTND
Resistors(10k,47k,75k,150k)Allresistorsshouldbe1/8wattorbetter.
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CF18JT10K0CTND
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CF18JT47K0CTND
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CF18JT75K0CTND
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CF18JT150KCTND
DCDCBoostConverter
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=29620500ND
Battery
http://www.lighthound.com/AWIMR186501600mAhLiMNrechargeablelithiumbattery_p_
2797.html
OR
(ifyouarecomfortablesolderingbatsyoucanusethesebutbeawaretheyareaverytight
fit)
http://www.lighthound.com/AW18650Protected2600mAhRechargeableLithiumBattery
NewVersion_p_3125.html
Mosfet
http://search.digikey.com/scripts/DkSearch/dksus.dll?WT.z_header=search_go&lang=en&si
te=ca&keywords=IRLU3114ZPBFND&x=0&y=0
KaptonTape(usefulbutnotessential,electricaltapewillworkifthat'sallyouhave)
http://www.dealextreme.com/details.dx/sku.5101
GeneralNotes
1. Themodissealedandnoairflowcomesfromthemodsoit'sfinetouseleadbased
solderifyouwant.
2. Iusesolid26gaugewireforthebuild.
3. ThefewplacesthatrequireepoxyIuseastandard2partepoxyandithasheldup
verywell.
4. Duringsolderingbesureallwiresaretinnedpriortoconnecting.
5. Ihaveassumedaminimalamountofexperienceforpeoplewhomightbeusingthe
guidetomakeamod.IapologizeinadvancetothemoreexperiencedmoddersifI
madeittoosimplistic.
AlternateLowerVoltageBuild
Forthosethatwanttheslidertooutputbetween4.0and4.5vthereisareallyeasytrick
thatRjGsharedwithme.Ifyouadda100kresistorbetweentheAdjpinandandvOutpin
ontheboosterthe4voltageswillbechangedto:
4.0v
4.15v
4.3v
4.5v
Thediodeinthebuildisstillrequired.
Theseareperfectvoltagesforthosethatdon'twantareallyheavyhitbutstilldesirea
reliablesolidhitsimilartowhatyougetwithalargefullychargedbattery.Thebestpartis,
theboosterisonlygenerating4.6vsoitalsoaddssomebatterylifetoeachcycle.
ThanksagaintoRjGagainforsharing.
Warning:DonotreducethevOutbelowthislevelastheboosterneedsheadroombetween
thesourceandoutputvoltage.Doingsocouldharmyourbooster.
Shortcut
Forexperiencedmoddersthatwanttoskipthewalkthroughandjustdotheirownversion,
hereistheparallelschematicthatgetsaddedtotheFistpack:
Note:IfyoudecidetoskipthewalkthroughIwouldrecommendthatyouatleastcheckthe
pointsontheboardthatshouldbeprotectedagainstshorts.
Disassembly
Remove4bodyscrews.
Carefullypryoffthetopcoverofthebody.Ifyoulookedatthetextonthesideofthemod,
thetopiswhenthetextisrightsideup.Whenpryingoffthetopcoverbecarefulwiththe
thinmetalpieceontheback.Itisheldby3plasticclipsonthebodyanditiseasytobreak.
Iuseasmallflatscrewdriverandslowlyworkmywayaroundthebody,gentlypryingasI
go.
RemovetheLEDPCBfoundonthesidecarefullymakingsureitisdoesnottouchanymetal.
Itisveryeasytoshortoutthisboardsobecareful.
Removethe2screwsonthemainPCB.
GentlyprythebatteryupandremovethePCBandbattery.Thebatteryisheldwithdouble
sidedtapeinthemiddleofthebatterysojustworkitabitwithasmallflatscrewdriverto
getthebatteryloose.RemovethebatteryandthePCB.
Note:Thecoverforthefuelgaugetestbuttonwilldropoutatthispoint,besuretostoreit
inasafeplaceforlater.
PullthebatteryawayfromthePCBanddisconnectthebatterytabswheretheyconnectto
thePCBusingasolderiron.Takecarefulnoticeofthecraptasticbatteriestheysupplywith
thebody.NeedlesstosaywewillNOTbestickingwithit.
Disassemblyiscomplete.
Note:Youcanputthebatteryawayaswe'renotgoingtobeusingit.Afteralltheexpense
andworkthatgoesintomakingthismoditmakessensetospendafewextrabucksand
useaqualitybattery.TheAWbatsI'vetriedgive4050%longerlifepercycle.
PCBModification
TofitallourowncircuitryintothebodywehavetoremovetheUSBoutportandafew
capacitorsthatwedontneed.
Toremoveacapacitor,justpullthecapstraightupusingapairofpliers.Theycomeoff
quiteeasily.Snipremainingleadsrightdowntotheboardensuringthattheremaining
connectionleadscannottoucheachothertoformashort.
ToremovetheUSBconnector:
Desolderthe2pointsshowncompletelyusingadesolderingbraid.Usingasmallflat
screwdriver,pryupthesideoftheconnector.Onceitislifted,Iwiggletheconnectorback
andforthuntilthe4leadsatthebackgiveout.IfthereareanyleadsattherearoftheUSB
portremainingattachedtothePCB,snipthemdowntotheboardandensurethereisno
materialleftthatcrossesbetweenthe4USBconnectionpoints.Doublechecktomakesure
noneofthe4connectionpointscanshortout.
OptionalStep
IhaveafriendwhowasusingafistpackthathadaUSBchargeportworkitselflooseafter
usingforawhile.Youmaywishtotakeafewminutesandstrengthensomeorallofthe
connectionpointsonthecornersoftheUSBport.
(Irecommendyoudothissincefixingit
laterisalotofwork)
Tapingtheboard
Therearetwokeyspotstoprotectontheboardtopreventshortsinthefuture.Iuse
kaptontapetoprotecttheUSBinputfromcontactingtheundersideoftheboostchipandon
thesmallresistorthatwillfitundertheslideswitch.
Preparingthemosfet
Ipreparethemosfetbeforeinstallingsinceitsaloteasiertoworkwithoutintheopen.
Turnthemosfetsothatthemetalplateisfacingup.Thepinsfromlefttorightwillbe
source,drainandgate.
Bendthegateandthedrainpinsupandclipthemtoabout5mminlength.Clipthesource
toabout3mm.
Tineachofthe3leadsonthemosfet.
Attacha10kresistorbetweenthesourceandthegate
Attacha3"redwiretothegate(farright)
Attacha3"blackwiretothedrain(middle)
Securingthemosfet
ThemosfetisattachedinthepositionshownandheldtothePCBusingasmallsolder
bridgebetweenthemosfetsourceandthebatterygroundterminalonthePCB.
Finalizingtheboardwiring
Attacha2"blackwiretothebatterygroundterminal(usedforbatteryconnect)
Attacha2"redwiretothebatterypositiveterminal(usedforbatteryconnect)
Attachasecond2"redwiretobatterypositiveterminal(usedtoconnecttothevoltagein
ontheboostchip)
Preparethebottomcase.
Dremeloffthetabsshowninthepicture.Becarefulnottoletthedremelchucktouchthe
body.Itendtoforgetaboutthisandhaveruinedquiteafewthisway.Iforcemyselftogo
slowandbeextracautioushere.Cleanoffanyexcessbitsbeforecontinuing.
Preparingthechromeframe
Attachthechromebacktothebottomcase.Drillordremmeltheholesfortheswitchand
theconnector.Iuseda901forthisbuild.Havealookatthelocationinthepicturebelow
forthelocationofthepushbutton.Ifyouuseadremeltomaketheholefortheconnector
goslowlyandmakeitassmallaspossiblesotheconnectorispressfitintotheframe.This
willhelptheconnectorstaysecured.
Usingacountersinkremoveathincircleofchromearoundtheatomizerconnection.Thisis
important.Youmustensuretherewillbenocontinuitybetweentheconnectionandthe
chromecase.
Separatethechromefromthebottomcase.Usingadremel,grindthechromefromthe
backoftheconnection,buttonandslideswitchholes.Thisistoensureasolidgripforthe
componentsandtoensuretheatomizerconnectiondoesn'ttouchthechrome.
Attacha3"redwiretothecentrepostoftheatomizer.Ifillthecentreholewithsolderand
thenattachtheleadtothere.Ifyoulookatthebackoftheconnectoryouwillseesome
slotscutintotheshell.Iattachthewiresothatitwillfallintooneoftheslots.Thisprevents
pressurefromthebatteryfrompushingthewireintothesharpedgeatthebottomofthe
connector.
Presstheatomizerintoposition.
Important:Testthecontinuitynowbetweentheconnectionandthechromebody.There
cannotbeanyconnectionhere.Ifyourmeterreads0.000orupthenyouhavecontinuity
andyouhavetoremoveanychromethatiscausingit.
Withtheconnectornowinposition,tinthetopoftheconnectionshellontheinside.
Attacha3"blackwiretothetopoftheconnectionshellwiththewirerunningtowardthe
pushbuttonopening.
Tintheleadsonthepushbutton.
Attacha1"redwiretooneofthepushbuttonleads.Tinbothends.
Insertthepushbuttonandscrewitintightwiththeleadthathasthewireattachedclosest
totheslotforthesliderswitch.
Theslideswitchcomeswith6pins.The2outsidepinsareacommon.
Clippins#2and#6offsincewewillnotrequirethem.
Tintheremainingleadsandclipthemtoabout3mmorso(seepic)
Nowwehavetosecuretheatomizerconnectandtheslideswitchtothechromebody.Itis
aLOTeasierifyoudotheseoneatatimetoavoidepoxyflowinginplacesyoudon'twantit
to.
Mixupyourepoxyandletitsitforaminuteortwotothicken
Addepoxyaroundtheedgesoftheatomizerconnectionandputsomeontheinsideto
ensuretheconnectiscompletelysealed.Thiswillpreventjuicefromenteringthemodand
causingallsortsofproblemslater.Donotbuildtheepoxyuptoohighsinceweneedallthe
spaceavailabletofitourbatterybackin.
Allowtheepoxytoset.
Oncetheepoxyhassetsothatitwillnolongerflow,mixupsomemoretoattachtheslide
switchandletsetforafewminutesuntilitisthickandtacky.Applyepoxytotheendsof
thesliderslotasshown:
Settheslideswitchintheepoxyandpositionproperly.Holdtheswitchinplaceuntilthe
epoxysets.Iusuallystopworkingatthispointforabout20minutestoallowtheswitchto
firmlysetbeforecontinuing.
Attacha3"blackwiretopin#1ontheslideswitch
Attacha150kresistortopin#3ontheslideswitch
Attacha75kresistortopin#4ontheslideswitch
Attacha47kresistortopin#5ontheslideswitch
Bendpinallpinsdownabit(seepicture)
Takethewireleadfrompin5andbenditsothatitrunsalongthetopoftheotherpins.
Soldertheotherresistorstothepin5wireandcliptheexcessfromallbutthepin#5wire.
Assembly
AttachthepreparedPCBtothebottomcasewejustpreparedandscrewinplace.
Attachthechromepiecebacktothebottomcase.Youwillhavetoputthefuelgaugetest
buttoncoverintheslotforitinthechromepriortosnappingthechromebackinplace.I
usuallyputthefrontpartonfirstandcarefullysnaptherestofthechromepieceinto
position.
Preboostwiring
Taketheredwirethatcomesfromthemosfetgateandconnectittotheopenpinonthe
pushbutton.
Taketheotherleadonthepushbuttonandconnectittothepositivebatterminalonthe
PCB.
Theboostpins
Preparingtheboost
Ifyouareusingaboostchipswithpinsthenclipthe4pinsdownabitontheboostPCB,tin
themandthensettheboostintoposition.Ifyouareusingoneoftheboostchipsthathave
4solderballsthenyoucanaddabitofsoldertoeachofthe4pointsontheboost.Thiswill
makeiteasiertomakealltheconnectionsrequiredfortheboostwiring.
YoucouldglueitdownifyouknowtheproperlocationbutIprefertoletitfloatasitmakes
anyfuturechangesorrepairsaloteasier.Italsomakessnappingthebatteryandtopcover
intoplacealoteasier.Ifyoufollowtheguideproperlythenthereshouldbenopossibleway
forittoshortonanything.
Seebelowforproperposition.
Boostwiring
Therearealotofconnectionsatthispoint.Justtackleitoneatatimeandyou'llget
throughit.
Withtheboostintheproperpositionrunthebarewirefromthesliderswitchresistorand
connecttothegroundontheboost.Thisconnectionwillhelpthebooststayinposition
whileyoudoalltheotherconnections.
Wirethecommonblackwirefromtheslideswitchtotheadjustmentpinontheboost
Wirethemosfetdraintotheresistwirejustbeyondthegroundpin.Iusuallywireall
remaininggroundwirestothisspotbecauseIfounditaloteasierthantrytoclumpthem
allontotheboostgroundpin.
Wiretheatomizergroundblackwiretotosamelocationontheresistwire.
Takethefreeredwirethatisattachedtothebatpositiveterminal(theonethatispointing
towardtheboost)onthePCBandconnecttotheVinpostontheboost
Usinga3"redwireconnectittotheVoutpost.
Tinbothsidesoftheschottydiodefromthepartslist
Note:Thediodehas2dotsonownsideand1dotontheotherside.Thesidewith1dothas
tobepositionedsothatthedotisfacingtheconnection.Ifyouputitinwrongyouwillnot
getpowertoyouratomizer.
CutandattachtheredwirefromtheVouttothe'in'sideofthediode.
Cutandattachtheredwirefromtheatomizerconnectiontothe'out'sideofthediode.
Youcaneitherprotectthediodeconnectwithshrinktubeortape.SinceIusuallytestthe
unitpowerunderloadIjustputsometapearoundthediode.
Addingthecapacitors
Idislikethispartbecauseyoubasicallyhavetoprotectthecapacitorsandthenstuffthem
in.I'vetriedrunningwithoutthecapsandyoucanseeandhearthedifferencesoI
recommendusingthem.
Preparethefirstcapacitor
Tinbothsidesofthecapacitor
Cutablackandaredwireto3/4"each,stripandtinsbothendsofeachwireandattach
onetoeachsideofthecapacitor.Keepinmindthatthepositivesideofthecaphasared
bandonitsomakesuretheredwiregoesonthisside.Tantalumcapshaveapositiveand
negativeside.Ifyoumixthemuptheywillpopwhenyouapplypower.
Iprotectthecapbytapinga2"pieceoftapearoundthecapandthenclippingtheexcessof
thetop.
Ifitthecapinfrontoftheboostchipandrunthewiresup.
ConnecttheredwiretotheVin
Connecttheblackwiretotheboostground
Preparethesecondcapthesamewayexceptusingalongerblackwire.Thewireshouldbe
justunder2"longandmustreachfromthegroundontheboosttothebackofthecase.
Iplacethiscapacitoratthebackofthemodnearthefuelgaugeboard.
ConnecttheredwiretotheVoutontheboostchip
Connecttheblackwiretotheboostground
Attachingthebattery(LiMN)
Solderathinstripofmetalorabatconnectortotheendsofthebatterywires.Tapethe
connectorstothebattery.Thiswillmakeiteasytoswapbatteriesdowntheroadwhenit
finallydies.Youshouldbeabletogetoverayearoutofeachbatteryevenifyouarea
prettyheavyvapersincethebatteryisnotstressedduringoperation.
Attachingthebattery(Liion)
Ifyouwentwiththe2600batitwillgiveyouahellofalotofvapetimepercycleandvery
longlife.Youwillhavetogrindoffthe3dimplesonthenegativeendandsolderthewires
straighttothebatkeepingthesolderveryflattogetthisbatterytofit.Ifyouhaven't
solderedtoLiionbatteriesbefore,thenusetheLiMNbatteriesinstead.
Important:Regardlessofthebatteryyouuse,oncesolderedmakeabsolutelysureyou
coverbothendsofthebatterycompletelywithinsulatingtapebeforeyousetthebatteryin
place.
AtthispointIusuallyruntests.Byplacingthevoltmeterprobes(positiveontheattycenter
hole)andnegativeonthebodyyoushouldhavenovoltagewhenthepushbuttonisnot
pressed.Takevoltagereadingsforeachoftheslidesettingswiththepushbuttonpressed.
Thereadingsareapproximateandwon'tshowtrueunderloadvoltagethisway(theywillbe
higher)butitwillgiveyoutheassurancethatthemodisworkingandthatthevoltageis
changingproperlyasthesliderpositionischanged.
Placethebatteryintopositionandtuckthebatleadsdown.
Atthispointyoushouldbeabletoattachanatomizerandvapetestit.
Preparingthetopcase
Dremeloffthetabsandridgesshowninthepicture.Aswiththebottomofthecase,be
carefulnottoletthedremelchucktouchthebody.Cleanoffanyexcessbitsbefore
continuing.
Attachthetopofthecase.Iusuallysetthefrontin(thesidewiththetestbuttonandslider)
andthenslowlysetitdown.Ifyouarehavingproblemsfittingthebodyon,checkforhigh
pointsontheboostchipsolder.Ifyoursoldersticksiptoohighitwillinterferewiththecase
closing.Reducetheheightofthesolderandretry.Thecaseshouldsnapintoposition.
Putbackthe4bodyscrews.
NormallyIvapethemodforabitjusttoensureitsallworkingandtorewardmyselffor
gettingthisfar.Onemorestepandwe'rehomefree.
Attachingthepushbuttoncap
Mixasmallamountofepoxyandletitgetreallytacky.Putabitofepoxyinthebottomhole
ofthepushbuttoncap.Donotoverdoit.Ifyougobitinanditrunsdownthebuttonyouwill
gettoexperiencethejoyofreplacingthebutton.
Whenthesmallbitofepoxyinthecapisabitsticky,gentlypushandtwistthecaponthe
pushbuttonpost.Turnthemodupsidedowntopreventanepoxyleakingdownthepostand
letitstaythatwayunlesstheepoxyissetandthereisnowayitcanflow.
Note:Ipaintedthisbodypriortobuilding.Ihavesincelearnednottopaintthem.ThePG
softensthepaintanditwearsoff.Badidea:)
Iusuallyplugintoacomputertotestthechargerwhilethecapfinishessetting.Afterabout
30minutesitissafetostartvapingaway.
Congratulations...themodiscomplete.Enjoy:)
Extrainformation.
Ifliquidaccumulatesonyourattyconnectionitcancauseaveryweakshort.Thesamecan
happenintheattyitself.Ifthefuelgaugelightsorthemodstopsworking,thenthereisa
goodchanceoneoftheprotectioncircuitshaskickedon.PluggingtheunitintoaUSBport
andunpluggingwillresettheprotection.Ifitcontinuestohappenthencleantheconnector
andchangetheatomizerandseeifitfixestheproblem.
AlternateBuilds
Therehasbeenrequestsforalternatebuilds.Recentlysomeoneaskedfora5vbuild.The
followingschematicsarethechangesrequiredtoremovetheselectorswitchandjusthave
itfunctionasasinglevoltageunit.