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Fistpackv2.

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.