Before I begin I'd like to make clear that I am posting this as a satisfied madvapes customer, not as an ECF moderator. This post mortem is intended to help any other Roughstack users that might be having switch issues as well as feedback to hoogie. With that in mind I ask that folks don't turn this thread into anything other than it's intent.
Background:
As you may have seen in some other threads here there is an issue where under high voltage vaping the spring in the switch can get hot, melting the plastic straw used to isolate the positive feed from the ground. when this happens the spring may touch against the inside wall of the battery adapter creating a short.
If this happens you can return your Roughstack to service by carefully removing the switch,cleaning the spring and reassembling the Roughstack. I know this because I have done it three times
Incident leading to postmortem:
Today I changed batteries and went to take a vape. Rather than getting a nice blast of vapor I got black smoke from the switch.
Postmortem results :
As an experienced helicopter crewchief and general mechanic of all things that fly fast make a lot of noise and make things go boom, I realized that letting the magic smoke escape is a bad thing! So i disassmebled the Roughtack and removed the switch.
Upon further inspection i noted that the plastic straw isolator had burned through and detached itself from the battery adapter, neatly fusing into a crinkly green doughnut of plastic. Inspection of the inner Isolator for the battery adapter center pin showed evidence of scorching, this is likely where the black smoke came from.
Inspection of the switch assembly showed melted plastic fused to the spring which in itself was not unexpected.
Repair attempt:
Noting that the isolator appears to be a length of plastic drinking straw I found a straw of proper diameter and trimmed it to properly fit the inside the battery adapter with the intent to put a small bead of hot glue to ensure it stays in place.
I then inspected and tested the switch to verify it was still working. (It was) Further inspection of the switch showed that the spring would likely touch the plastic straw and melt it again because there was a noticeable "list" to one side.
I gently attempted to straighten the spring and of course it snapped in two places. Inspection of the spring pieces and my experience lead me to believe that this breakage was induced by tempering of the spring form the times it got too hot and melted the plastic. Of course without spending money to have the spring rockwell tested it is just an educated guess.
Analysis of possible solutions for end users:
For those people that wish to "fix" this problem if it occurs on their Roughstack I would recommend that you preform these steps before you mamange to burn an isolator or harden the spring to the point of becoming brittle:
1. Make sure the spring is straight and not too long. If the spring is crooked and long, compressing the spring when you install the switch will push it into the isolator.
2. Carefully reduce the diameter of the spring at the contact end by about 33%. This will reduce the possibility of that end contacting the isolator.
Closing:
I'll probably post again with results after I repair the switch assembly and finish "rebuilding" my Roughstack. If this fails I'll probably order a replacement switch. (or maybe I will just because I like my Roughstack and having a spare switch is not a bad idea).
I have no doubt from my past dealings with MadVapes that hoogie would "make it right" if I were to simply put in a support ticket, but the truth of the matter is that I can probably fix it if I am careful. The only thing wrong with the switch is the spring and the only thing wrong with the "upper" is a missing piece of drinking straw and a slightly scorched pin isolator.
Background:
As you may have seen in some other threads here there is an issue where under high voltage vaping the spring in the switch can get hot, melting the plastic straw used to isolate the positive feed from the ground. when this happens the spring may touch against the inside wall of the battery adapter creating a short.
If this happens you can return your Roughstack to service by carefully removing the switch,cleaning the spring and reassembling the Roughstack. I know this because I have done it three times
Incident leading to postmortem:
Today I changed batteries and went to take a vape. Rather than getting a nice blast of vapor I got black smoke from the switch.
Postmortem results :
As an experienced helicopter crewchief and general mechanic of all things that fly fast make a lot of noise and make things go boom, I realized that letting the magic smoke escape is a bad thing! So i disassmebled the Roughtack and removed the switch.
Upon further inspection i noted that the plastic straw isolator had burned through and detached itself from the battery adapter, neatly fusing into a crinkly green doughnut of plastic. Inspection of the inner Isolator for the battery adapter center pin showed evidence of scorching, this is likely where the black smoke came from.
Inspection of the switch assembly showed melted plastic fused to the spring which in itself was not unexpected.
Repair attempt:
Noting that the isolator appears to be a length of plastic drinking straw I found a straw of proper diameter and trimmed it to properly fit the inside the battery adapter with the intent to put a small bead of hot glue to ensure it stays in place.
I then inspected and tested the switch to verify it was still working. (It was) Further inspection of the switch showed that the spring would likely touch the plastic straw and melt it again because there was a noticeable "list" to one side.
I gently attempted to straighten the spring and of course it snapped in two places. Inspection of the spring pieces and my experience lead me to believe that this breakage was induced by tempering of the spring form the times it got too hot and melted the plastic. Of course without spending money to have the spring rockwell tested it is just an educated guess.
Analysis of possible solutions for end users:
For those people that wish to "fix" this problem if it occurs on their Roughstack I would recommend that you preform these steps before you mamange to burn an isolator or harden the spring to the point of becoming brittle:
1. Make sure the spring is straight and not too long. If the spring is crooked and long, compressing the spring when you install the switch will push it into the isolator.
2. Carefully reduce the diameter of the spring at the contact end by about 33%. This will reduce the possibility of that end contacting the isolator.
Closing:
I'll probably post again with results after I repair the switch assembly and finish "rebuilding" my Roughstack. If this fails I'll probably order a replacement switch. (or maybe I will just because I like my Roughstack and having a spare switch is not a bad idea).
I have no doubt from my past dealings with MadVapes that hoogie would "make it right" if I were to simply put in a support ticket, but the truth of the matter is that I can probably fix it if I am careful. The only thing wrong with the switch is the spring and the only thing wrong with the "upper" is a missing piece of drinking straw and a slightly scorched pin isolator.
