Antharak
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Tutorial
How to make a dummy spacer for use in a 2xAAA pointer when using a 10440 Li-ion for about a buck
Things you need
A PILOT easy touch fine pen.
Fine saw or serrated knife
Aluminum foil 6”x3” piece
AWG 18 solid copper wire or multi strand
Small flathead screw driver
Large driver with a square bit
12”x12” piece of cloth
120 grit emery
Drill or Dremel like device
1mm drill bit
Black sharpie
Take the pen apart and cut a 43mm piece off the clear piece. Use the threaded end
Sand the cut end square
Cut 1”x6”” strips out of the foil, fold and lightly twist the foil to fit
Using the small screwdriver push the strips of foil into the pen
Every 3 pushes pound the foil to compress it. s
When you get halfway, fold the cloth and put the piece on it and realy pound on the driver. This will make the foil extend past the edge of the tube.
When you get to the last strip be sure to leave a tab to fold into on the strip before it.
Make it as compressed as you can, don’t use a hammer or you will crack the piece. It should look like this
Next put the emery on a flat surface and sand down the end that you put the foil in,not the end that the foil protrudes from. Do this till the piece is 42.28mm or as close as you can, a little longer is better than short. Sand any rough edges and make sure the foil wont touch the side of the case when used.
Almost finished
No pics of the drilling, I don’t want aluminum dust in the house
Drill a hole the length of the piece in the center or close to it.
Slide the bare copper wire through the piece cut it 1mm out from each end.
Put it on a hard surface and pound it flush with one end and remember one end sticks out slightly.
The copper wire is needed as the aluminum has about 2 ohms of resistance because of multi contact points. Even if you use a single piece of foil this will still happen.
Now paint it with the sharpie and you’re done.
This all took about 25 minutes
This one gave a resistance reading of 0.01 Ohms
When you use it put the sanded side towards the spring to be sure to make good contact.
I did it this way ,as it was all I had on hand
:beer:
6/16/2013
UPDATE
The unit works fine, but after reading the posts below, I realized the German in me was coming out.
I needed another one so this time I took 12AWG cord cut it to length 4 pieces, striped off the insulation about .100 on each end. Taped the four together and pushed the exposed wire into the center area. works fine, took 5 minutes and cost les than 20 cents.
here's a pic
How to make a dummy spacer for use in a 2xAAA pointer when using a 10440 Li-ion for about a buck
Things you need
A PILOT easy touch fine pen.
Fine saw or serrated knife
Aluminum foil 6”x3” piece
AWG 18 solid copper wire or multi strand
Small flathead screw driver
Large driver with a square bit
12”x12” piece of cloth
120 grit emery
Drill or Dremel like device
1mm drill bit
Black sharpie
Take the pen apart and cut a 43mm piece off the clear piece. Use the threaded end
Sand the cut end square
Cut 1”x6”” strips out of the foil, fold and lightly twist the foil to fit
Using the small screwdriver push the strips of foil into the pen
Every 3 pushes pound the foil to compress it. s
When you get halfway, fold the cloth and put the piece on it and realy pound on the driver. This will make the foil extend past the edge of the tube.
When you get to the last strip be sure to leave a tab to fold into on the strip before it.
Make it as compressed as you can, don’t use a hammer or you will crack the piece. It should look like this
Next put the emery on a flat surface and sand down the end that you put the foil in,not the end that the foil protrudes from. Do this till the piece is 42.28mm or as close as you can, a little longer is better than short. Sand any rough edges and make sure the foil wont touch the side of the case when used.
Almost finished
No pics of the drilling, I don’t want aluminum dust in the house
Drill a hole the length of the piece in the center or close to it.
Slide the bare copper wire through the piece cut it 1mm out from each end.
Put it on a hard surface and pound it flush with one end and remember one end sticks out slightly.
The copper wire is needed as the aluminum has about 2 ohms of resistance because of multi contact points. Even if you use a single piece of foil this will still happen.
Now paint it with the sharpie and you’re done.
This all took about 25 minutes
This one gave a resistance reading of 0.01 Ohms
When you use it put the sanded side towards the spring to be sure to make good contact.
I did it this way ,as it was all I had on hand
:beer:
6/16/2013
UPDATE
The unit works fine, but after reading the posts below, I realized the German in me was coming out.
I needed another one so this time I took 12AWG cord cut it to length 4 pieces, striped off the insulation about .100 on each end. Taped the four together and pushed the exposed wire into the center area. works fine, took 5 minutes and cost les than 20 cents.
here's a pic
Last edited:
