1. VAPOUR101
2015The variable voltage/wattage sub ohm vape box with LCD display
Stephen Parker
Vapour box
v2.0 designed by: Stephen Parker
V A P O U R 1 0 1 , 6 H I L L V I E W T E R R A C E , N E W M A R S K E , T S 1 1 8 E P
0 7 8 7 1 6 5 4 9 0 1

2. StephenParker
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Unique vv/vw sub ohm box with LCD display
Briefdescriptionof design
Thisdesignwill be completelyunique asi have noticedalot of people wantsomethingdifferent
fromeveryone else,the followingdesignwill includeaprocesscalledswirl paintinggivingeverybox
unique stylesandpatternsnobox will be the same looking. Ihave alsoaskeda lotof people what
theylike tosee ontheircigarettesanda lot of themhave saidtheywouldlike ascreendisplayon
theirdevice toshowthe voltage andwattage as well asbatterylevel of the device,i have sourceda
DNA chip capable of doingthese exactthingsandmore suchas manuallyoverride the wattsfrom
7watts to 30watts so userscan setthere device totheirrequiredneedsthischipalsofeaturesalock
so youcan lock the device andnotworry aboutthe device heatingupinyourpocket.Anotherthingi
noticeda lotof people like isandadjustableatomiserconnector,whichthisdevice will have. There
will be fusesinstalledintothe deviceasa safetyfeature toprotectthe batteriesfromtoohighamp
loads.There will alsobe aClearPolycarbonate windowadded tothe device togive thisdevice a
professionallookandfinish.
Parts requiredfordesign – with parts info
DNA 30D board with LED screen/chip& micro USB charging board £23.79
DNA 30D 30Watt variable powermodule withOLEDdisplayThe DNA30Disa
powerregulateddigitalswitch-mode DC-DCconverterforpersonal
vaporizers.Itfeaturesasmall OLED display,analogueordigital usercontrols,
onboardbuttonsand synchronousrectificationformaximumbatterylife and
minimal heatgeneration.
http://www.ebay.co.uk/itm/Replacement-Board-LED-Micro-USB-Wall-
Charger-DNA-30-Mod-Chip-7W-30W-DIY-
/281435881125?pt=LH_DefaultDomain_3&hash=item4186e2bea5
Hammond 1590ABK box - £3.56 – to mounteverythinginside
Body Colour:Black
Enclosure Material:AluminiumAlloy
Enclosure Type:Instrument
External Depth - Metric: 31mm
External Height- Metric: 93mm
External Width - Metric: 27mm
IPRating:IP54
NEMA Rating:12K
SVHC:NoSVHC (16-Jun-2014)
http://uk.mouser.com/ProductDetail/Hammond-
Manufacturing/1590ABK/?qs=4dK74SdgGtwN7aPBfm0Hzg%3D%3D

3. StephenParker
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510 connector- £1.95 – to mountany atomiserontothe box.
DedicatedBottom-Feeder510s basedonthe provenV4
design.Comeswithfoodgrade stainlesssteel centre postwith
a 1.75mm hole fora generousjuice flow.Tail isextendedto
12mm (9mmusable) foreasiertube deployment.Also
includedisabrass soldersleeve since itisapainto solderto
stainlesssteel.Pryitopentoon the gap tightentotightenand
soldertosecure.(Itisrecommendedthatthe leadwire be
solderedfirstonthe 2mmhole of the soldersleeve.)
http://www.fatdaddyvapes.com/shop.html
battries - £10.50 – these will be wired inparalleltoachieve atotal of 2400mAh
The itemis a professionalandpractical 3.7V rechargeable Li-po
battery,whichissuitable forWalkera 5G4Q3 5#10, GYRO
HerculesUnbreakable RCHelicopterZX-35850, or can be
widelyusedonR/CMini car, truck, boathelicopter,
airplane...etc.Itfeatures1200mAhhighcapacitywiththe
continuous discharge rate upto 25C, thenyou needaLiPo
balance chargeris requiredtocharge thisbattery.
Specification
- Batterysize:7cm*3.2cm*0.6cm (L*W*H)
- Colour:as showninthe pictures.- Material:Lithiumpolymer.
- Plug-type:JSTplug.
- 100% brand newandhighquality3.7V 1200mAh 25C Rechargeable LipoBattery.
- Voltage:3.7V.
- Capacity:1200mAh.
- Maxi continuousdischarge rate:25C.
- Workingtemperature:0°C~45°C (charger); -20°C~60°C (discharger).
http://www.ebay.co.uk/itm/2Pcs-3-7V-1200mAh-25C-Lipo-Battery-For-Walkera-5G4Q3-5-10-Syma-
S006G-MJX-R-C-F29-/391180036239?pt=LH_DefaultDomain_3&hash=item5b1425a88f
4x Fuse £0.16 - for amp loadsafety
HoldCurrent:3 A
Trip Current:5.1 A
CurrentRating- Max: 100 A
MaximumVoltage:16 VDC
Resistance:97.5 mOhms
TerminationStyle:Radial
Series:USBR
OperatingTemperature Range: - 40 C to + 85 C

4. StephenParker
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Lead Spacing:5.1 mm
Dimensions:11 mm L x 7.1 mmW x 3 mm H
Type:PolyFuse Resettable PTC
http://uk.mouser.com/ProductDetail/Littelfuse/16R300GU/?qs=ZSIFh4sPSRouCQaFuDECOQ%3D%3
D
Tactile Switches£0.47 - for toggle switches (mainlywattage upanddownbuttons)
OperatingForce:2.9 N
Brand: C&K Components
Actuator:Dome
CurrentRating:50 mA
Voltage RatingDC:32 VDC
PowerRating:0.2 VA
Ground Terminal:No
Contact Form:SPST
SwitchFunction:OFF - (ON)
TerminationStyle:solderPin
MountingStyle:ThroughHole
MountingDirection:RightAngle
IP Rating:IP60
Contact Plating:Silver
Series:KSJ
Factory Pack Quantity:250
Travel:1.2 mm
Part # Aliases:LFTY33A431N5FP Y33A431N5FPLFT
http://uk.mouser.com/ProductDetail/CK-
Components/KSJ0M43180SHLFT/?qs=8LLMQjkBYsIQvOYeECRfXQ%3D%3D
20 Guage Red & Black wire £15.28 (£0.61 per foot) – to connectall the
connectionstogether
(25 ftlongwire) 20 gauge recommendedforuse withthe chosenchip
http://www.ebay.co.uk/itm/20Guage-25-Ft-12Vdc-Wire-Red-Black-2-
Conductor-
/311298886574?pt=LH_DefaultDomain_3&hash=item487adc0bae
Solderingiron £6.99 – to solderthe wiresintoplace
30W-240 Iron
Brand: Marksman
Britishstandardplug
Has a neatnibto ensure accurate distributionof the solder.

5. StephenParker
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http://www.ebay.co.uk/itm/30W-60W-ELECTRIC-SOLDERING-IRON-KIT-SOLDER-GUN-KIT-
DESOLDER-LEAD-WIRE-PUMP-BNIB-/111476586964?_trksid=p2141725.m3641.l6368
Solder£1.89
20G TUBE OF SOLDER
60/40 TIN/LEAD
Flux-covered
For electrical andelectronicwork
http://www.ebay.co.uk/itm/20G-TUBE-60-40-TIN-LEAD-SOLDER-WIRE-
FLUX-COVERED-ELECTRICAL-SOLDERING-DIY-HOBBY-
/181452656168?pt=LH_DefaultDomain_3&hash=item2a3f6bce28
flux£1.90 – forcleansolidconnectionsandnodry joints.
Medium-active flux thatfacilitatessolderingof the followingelements:
copper,silver-plated,zinc-coatedandnickel-plated
http://www.ebay.co.uk/itm/Electronic-Solder-Flux-Paste-to-Avoid-Dry-
Joints-40g-/141490692497?pt=LH_DefaultDomain_3&hash=item20f180a191
heat shrink £4.99 (£0.018 persleve) - To preventshortsinthe box and
protectsolderwork.
MinimumShrinkage Temp:+70°C
Full Shrinkage Temp:+110°C maximum
OperatingTemperature: -55°Cto +125°C
Tensile strength:10.4Mpa
Dielectricstrength:15kV/mm
Flammability:Flame Retardant
Suppliedformat(roundorflat) :Productis suppliedflat
Cuttingmethod:Scissorsorsharpknife
Manufacture specification:ISO9001
Approvals:UL Approved
To preventshortsinthe box
http://www.ebay.co.uk/itm/280-Pcs-Heat-Shrink-Car-Electrical-Wire-Tubing-Tube-Sleeving-Wrap-
Cable-Kit-/400915303115?pt=LH_DefaultDomain_3&hash=item5d586a0acb
Double sidedtape £2.40
To secure batteriestogether

6. StephenParker
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Epoxy resin£2.49 – to secure some of the componentsused.
Epoxyadhesive glue glasswoodleatherplastic
Sticks:ceramic,glass,wood,leather,fibreglass,
Plastic,paper.....etc
Quicksetting:4-6 minutes
Epoxyadhesive automaticallydispensesintoequalparts
With1 push.
Perfectforbondingglass,metal,china,woodandfibreglass
www.amazon.co.uk
Clear polycarbonate palram perspexplasticsheet £1.99
Used forthe window onthe box (replace the metal box lid)
www.ebay.co.uk
Tint film£4.49
Usedto give the box a stylish professional lookoverthe windowedpartof
the box that will replace the lidof the Hammondbox.
www.ebay.co.uk
Fire button £3.30
Usedto activate,lockand changesmodesonthe device.
http://www.modmaker.co.uk/Mod-Making-
Supplies/Switches/12mm-Green-LED-Metal-Illuminated-Switch-Flat-
Raised-Actuator

7. StephenParker
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total cost
For start up includestools=£72
Each standard box (nocustomparts or window) will costtobuild=£42 retail price = £57 (£15 profit)
Customboxeswill range from - £52 to £150 dependingoncustomerdemands.
Pre-assemble
Preparation before swirl painting (done after drilledout holes)
Before we startto buildourbox we needtodo our swirl paintjobtogive the box a stylishunique
professionallook.Sotodothiswe needenamel paints(colourspickedbycustomer),we alsoneed
some flatprimer(nogloss) tospray the box with, andthis providesagood surface forthe paintto
stickto. To protectthe box we needsome clearcoatspray. We will alsouse some painterstape this
will be usedforanypart of the box the customerdoesnotwantpained(canbe usedfor cut out
designsonthe box as well).We alsorequire tohave acontainertoholdwater(thismustbe big
enoughtofullysubmerge the box intothe waterwithouttouchingthe bottomorsidesof the
container.We needtoachieve atemperature of 25 degreesCin the wateras well soa waterheater
may be required.We will use borax powdertohelpthe paintfloatonthe top of the water.Pipettes
will be usedtoadd little dropletsof painttothe water.Finallywe use aflatshapedstirstick,thiswill
helpusmove the paintaroundand make swirl patternsinthe paint.
Swirl painting
1. We take our box withoutthe lid,usingpainterstape we coverall the insideandanyother
area’sthat we do not wantthe paintto be on.
2. We will nowcoverthe box withthe primer
3. Nowfill ourcontainerwithwaterandrecordhow muchwater we are adding.
4. Addthe water heaterandsetit to 25 degreesc(normal roomtemp)
5. Once the water isheatedto25 degreesCwe addthe requiredamountof borax (ratio= 1
and a half table spoonsper4.5 litres)
6. Nextwe stirthe mixture ensuringall the borax hasdissolved
7. Nextwe will remove the waterheaterandstartapplyingourpaintsto the surface of the
waterstartingwiththe darkestcolourfirst.
8. Nowwe take our stir stickand slowlymove the paintaroundtill we achieve agoodlooking
swirl pattern.
9. Nowwe will slowlystartapplyingourbox tothe paintinsertingthe box ona angle sowe
don’tgetany flatsidesandslowlymove the box fromside toside aswe submerge the box
to collectthe paintandget a wavylookto the box.
10. Once the box isfullysubmerged,take your
stickand move all the paintaway fromthe
surface of the wateronce it looksclearwe can
remove ourbox fromthe water.
11. Nowwe can see what the box will looklike we
will nowhangthe box until it’sfullydryand
thenprotectit usingthe clearcoat.

8. StephenParker
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The swirl paintwill looksomethinglike this:
Image takenfrom: http://kopics.com/wp-content/uploads/2015/05/Paint-Swirl-Free-
Wallpaper-Desktop.jpg.
The buildprocess
Firstof all we shouldlookathow to wire thischiptoour othercomponentswe can dothis
by lookingatthe manufacturesdatasheet.
Image takenfrommanufacturesdatasheetfoundhere:
http://www.evolvapor.com/datasheet/dna30.pdf

9. StephenParker
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Wieringdiagram
As i had no accessat thistime toscematicsi had to draw my diagramusingpaint.
To make things easierformyself i createdthiswieringdiagram.
Wiring
Because number16 in the diagram(onboard fire switch) isuselesstousas where fittingourown
switchwe will remove the onboardswitchtosave room as the box is quite small we needtomake
as much roomas possible where we can.
Nowwe can proceedto followthe wiringdiagrami createdabove and solderall the wiresasshowni
do thisbyaddingflux tothe wire andsolderthenplace the wire inthe requiredplace onthe board
and justtouch the endof the wire where the connectionneedstobe made withthe tipof the
solderingironandthe solderwill flowontothe requiredplace of contactand repeatthisforeach
connectiononthe board.
On the up anddowntoggle switchesthere is4 legsbutwe onlyneedtoso whatwe will doiscut off
2 of the legsonone side andbenddownthe other2 legssothere flatfor solderingtoandagain
savingspace.Nowwe will addthe positive andnegative wirestothe buttonsbyapplyingflux again
and solderingontoeachleg(thisprocessisrepeatedforthe upand forthe downswitch),we now
add heatshrinkto bothlegsandheat themup carefully ensuringwe don’tburnanything till they
have shrunkaroundeach wire thisalsogivesanice clean lookto the buildwhile alsoprotectingthe
box fromshort circuits.
Nextwe will workonthe Lipobatterieseachratedat 1200mAh and we will connectthemtogether
inparallel togeta total of 24000mAh while maintainingthe 3.7V,to connectthese batteries
togetherinparallel we willtake boththe positivewiresfromeachbatteryandconnectthem
togetherthendothe same for the negative wire.Firstof all where goingtouse the double sided

10. StephenParker
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tape to tape the 2 batteriestogether,now we willcutoff the connectorsonthe batteries leaving
about1 inchof wire while beingverycareful nottoletthe opennegative andpositive wiresconnect
witheachotheras thiscouldbe verydangerous. Now we need43A fusesconnectedinparallel to
create a 12A fuse. The firstpositive wire willconnectto2 fusesandthe secondpositivewire will also
connectto 2 fusesthenonthe otherside of all the fusestheywill all connecttogetherinto1positive
wire makinga total of 12A fuse.
Nowwe will workonthe micro usbcharging portfor the device,all we needtodohere issolderthe
negative andpositiveterminals.
Nextwe will solderthe negativewire tothe base of our 510 connectorand the positive wire tothe
centre pin and applyheatshrinktoboth wires.
Andfinallythe firingbuttonhas2 pinsall we needtodo ischoose a pinfor negative andone for
positive thensolderthemonandapplythe heatshrink.
Clear window
Nowusingour Clearpolycarbonate Perspex plasticsheetwe have 2options
Option1) place the box directlyontopof the Perspex sheepanddraw arounditwitha pen
Option2) usingthe dimensionsof the box 31mmx93mmx39mm(D*H*W), mark outthe
measurementsonthe Perspex sheetandcutit out andsmoothoff the corners.
Thenwe will pinpointwhere eachscrewhole needstobe on the cut out window anddrill outthe
holesrequiredandthencountersyncthemsothe screwssitflushwiththe window.
Epoxy
Withshort circuitsinmindi will applyasmall square of Perspex andEpoxyittothe bottomof the
microUSB chargingboard,and thenwe will applymore Epoxytothe bottomof the Perspex to
attach it to the bottomof ourbox doingthiswill alsoraise the chargingportfromthe verybottomof
the case up a fewmmand thiswill furtheraddtothe professional lookingfinish.
Nowwe will Epoxythe 510 connectorand the toggle powerupanddownbuttonsto the case.
Double sidedtape
Nowwe will insertthe batteriesintothe bottomof the case usingthe double sidedtape (sothey
may be removedandreplacedif needed)
Thenwe will take the DNA 30D board and place the wiresfacingthe correctdirectionsastheywill go
inside the case thenusingthe double sidedtape againwe will tape the LCDscreendirectlyontopof
the DNA board.Nowwe will place the DNA usingdouble sidedtape directlyontothe topof the
batteriesinthe middle of the whole box (againthiswillonlybe doublesidedstuckdowninthe event
that the batteriesneedreplacingatanystage).

11. StephenParker
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Final wiring
Nowall we needto dois followthiswiringdiagrami createdandconnectall the wirestogetherasat
thisstage the wiresare in2 half forall the components,itwasdone like thistomake the building
processeasierformyself.Before solderingall the wirestogetherwe needtoapplyheatshrinkto
each wire thensolderthemall thenuse aheatgun to shrinkthe heatshrinkovereachsolderedwire.
extras
These extrasare what makesthisbox completelyunique tothe userasthere isalmost100% no
chance anyone will have abox that lookslike there’s.
Tintthe clearPerspex windowanycolourthe customerrequires –todo thiswe will applytintfilmto
the Perspex.
Wide range of buttonswithledlightsorwithoutthatcustomerwill be able tochoose from(fire
buttonand the powerupand downbuttons).
Wide range of optional differentmetal,differentcoloursforthe 510 connectorcap.
Wade range of coloursto pickfrom for the swirl paintjob.
The customercan email patternsorlogosthattheywouldlike onthe backof theirbox.- todo this
we wouldcreate a stencil usingthe painterstape forthe logoorpattern theywantand applyitto
the back of the box priorto doingthe swirl paintthenwe couldpeal the stencil off.

12. StephenParker
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About the DNA chip
The normal,special operatingmodesanderrormessagesare shownonthe displayare shown
below.
Takenfrom the manufacturesdatasheet: http://www.evolvapor.com/datasheet/dna30.pdf

13. StephenParker
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Reason for picking20 gauge wire
(image frommanufacturesdatasheet: http://www.evolvapor.com/datasheet/dna30.pdf)
As youcan see inthe chart above the maximumwire size is20gaugeswire hence whyall the wires
inthisbuildare 20 gauges,thisisto make the device more costefficientsowe don’thave to
purchase multiple sizesof wire.

14. StephenParker
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Reason for buildingthe box
Reasonsforme designingthisbox are:
1) I have noticeda large numberof people complainingaboutthere batteriesdyingtooquickly.
2) People alsolike devicestobe differentandunique tothemselves.
3) I wantedtodesignE-cigarette thatcan comfortably sitinyourpocket.
4) I have alsonoticedsome very expensive e cigarettes onthe marketandwantedtobuild
somethingwithall the featurespeople wantata low cost while maintainingthe stylish
professionallook.
5) There isa highdemandforhighpowerede cigdevices.
6) The market forelectroniccigarette devicesitgrowingatarapid rate.
7) I wantedtodesigna box witha micro USB charger so the box can be usedwhile being
chargedunlike othere-cigarettes.
8) Most people wanta device capable of producingalotof flavour.
9) People liketoadjusttheirvoltage/wattageontheirdevices.
10) I wantedtomake a device withsafetyfeaturesasalot of e-cigarettesonthe marketare not
safe.
11) People likethe abilitytouse anytype of atomiserontheirdevice.
12) Supportfor coilswithlessthan1.0 Ohms.
13) Wantedto designasimple device touse tomake ituser friendly.
14) Completelycustomisable tohowthe customerwouldlike the product.
15) Large companies are investingin ecigproducts.
marketing aimedat smokers
Will be presentedas:
• A healthierandsafersource of nicotine thantraditional cigarettes.
• Goodfor cuttingdown,quittingorswitchingfromtraditionalcigarettes.
• Suitable foruse insituationswhere the smoke freelegislationapplies;andwithoutreleasing
harmful second-handsmoke.
• tastingsimilartotobacco,but cleanerandmore fragrant.
• Cheaperthantraditional cigarettes,backedbypromotional pricingforstarterkitstoincentivise
trialsby committedsmokersandpricingoffersaimedatretailerstokeepstockoutlaystoa
minimum.
•Promotional piecessuchasnews-generatingsurveys,competitions,pressreleases,advertsand
paid-foradvertorialsinthe popularandtrade pressare commontactics.
•One brand sponsoredafree publiclecture one-cigarettes(withrefreshments) ata universityto
‘explainwhattheyare,howtheywork,whethertheyhelppeoplestopsmokingandwhetherthey
are safe’(NewhamRecorder).
•Televisionadvertsfore-cigarettesalsotargetthe committedsmokerwhoisconsideringquitting.

15. StephenParker
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•Overall forthisconsumergroup,e-cigarettesare positionedbythe independentcompaniesasa
normalisednecessity –the ultimate,sociallyacceptable,smokingalternativeforsomeoneaddicted
to nicotine.
Marketing aimedtowards current e-cigusers
 Longerlastingbatteriestimes
 Compatible withall atomisers
 Safe to subohm on
 User friendlydevice
 Highlycustomizable
 Made Unique toeveryuser
 Variable voltage/wattage
 Lcd screendisplay
 Stylishwithoutthe highprice tag
Company logo design

16. StephenParker
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CAD drawings
Righthand ride of box
top of box
all othersidesremain
untouched.