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After a couple of years of heavy use my Dremel VersaTip's igniter broke, allowing me to use the tool but having to use a lighter or a match to fire it up, since it's an excellent and handy tool, i couldn't let it go that easy without at least trying to fix it.

The Result:

The tool is back in business!

Step 1: Tools Needed for the Job

- An old lighter (or new, but you have to make sure to empty it first carefully).

- A Torx #7 screwdriver.

- Spare tiny cable (single wire)(you can even use the one that came with the original igniter).

- Electrical tape.

- Fine tweezers.

Step 2: The Problem

A broken igniter

Step 3: The Disassembly

Note of precaution: MAKE SURE THAT THE BUTANE CANISTER IS EMPTY BEFORE STARTING

- Unscrew the Catalyst. Flame Guard, Flame Guard Nut and the Ceramic Insulator.

- Use the T7 screwdriver to remove the 4 screws on the side of the Dremel VersaTip.

- Carefully remove the side cover (avoiding that some of the pieces fall from their place).

- Separate the nozzle from the back cover but don't remove the hose

Pay attention to the next step because there is a tiny piece of metal with a rod attached to the center of the trigger.

- Remove the trigger by simply lifting it (Be careful, the big spring attached to the igniter will jump out of it's place).

- Remove the little piece of metal with the rod in the middle (Don't separate them).

- Remove the damaged igniter and save the big spring.

Step 4: Getting the "New" Igniter and the Preparation

Take the EMPTY lighter and start taking it apart using some force, but don't break the whole thing so you won't make a mess or damage yourself (there are a few videos in YouTube).

Recover the igniter from the lighter.

The old igniter's cable is 1 3/4" (4.5 cm), so we need to extend the new one to that length by cutting a piece of the old one, peel it and attach it to the cable of the "new" one make sure you secure it with some electrical tape to avoid risks later.

Make sure to peel the end of the cable so it will drive the current and work the way it is suppose to be, the peeled tip should be around 1/8" (4 mm).

Step 5: Reassembly

- Start with placing the igniter back into place, making sure that the naked part of the cable fits in the proper place (us the tweezers to place the end of the cable where it belongs).

- Slide the metal rod into the trigger.

- Place back the big spring.

- Adjust the trigger back into place.

- Make sure everything fits back where it belongs.

- Place the side cover back in.

- Place the screws but don't tighten too much.

- Screw the Tip, the Flame Guard, the Flame Guard Nut and the Catalyst back.

- Test it.

Step 6: Done!

Hope you liked this Instructable and please leave your feedback.

Thank You.

<p>My Igniter broke as well, I might try doing this soon. But there is a second problem. After filling it up with fresh Butane again, the flame looks weird. It doesnt look like strong, stable jet flame, but rather like a wobbly lighter flame from normal lighters. The flame sometimes isn't even blue anymore. Does anyone have a similar problem?</p>
<p>I think that you have 2 problems here... first, the tip of the nozzle might be dirty or clogged, try cleaning it with a needle and remove any sediment, and second, the butane you re using might not be from good quality, you should use a good butane to avoid sediments ar anything in the nozzle, you should also check that the hose is in good shape and well attached. Hope this can help you</p>
<p>I tried cleaning the Diffuser, the part that mixes the gas with some oxygen to create a blue flame with abrush, I'll try cleaning it with chemicals soon, maybe with vinegar. So far, the flame is still yellow, kinda looks like a small flamethrower rather than a jet flame. Maybe better butane will work, but I will comment when I finally found a solution.</p><p>By the way, I tried your Instructable to replace the igniter, at least it ignites the flame every time I press now!</p>
<p>I tried cleaning the Diffuser, the part that mixes the gas with some oxygen to create a blue flame with abrush, I'll try cleaning it with chemicals soon, maybe with vinegar. So far, the flame is still yellow, kinda looks like a small flamethrower rather than a jet flame. Maybe better butane will work, but I will comment when I finally found a solution.</p><p>By the way, I tried your Instructable to replace the igniter, at least it ignites the flame every time I press now!</p>
<p>Thanks for the instructable. After opening up the side cover, I tried clicking the trigger and noticed that a spark was being generated but it wasn't coming out at the end of the metal rod but further down closer to where the rod passes through the trigger. I then discovered that the rod was not seated properly within the plastic groove below it, so I pushed it down with my 2mm flathead screwdriver and &quot;voila&quot;&mdash;when I depressed the trigger the spark came out at the end of the thin metal rod. After putting it all back together and refilling the tank with butane, I held my breathe, pulled back on the trigger and it lit up instantly! Saved me much time and a little money by not having to buy a lighter. If I hadn't followed your instructions to open up the side cover, I would have never discovered the simple problem with my Versatip. </p>
<p>Glad I found this! My ignitor works about 5% of the time and I've only had is 5 months! I click and click and click and finally it will come alive!</p>
<p>I'm glad this instructable is helpful, you should check the grounding rod, maybe is not making proper contact with the flame guard which is the one that transfer the current to the catalyst, use a tweezer to slide it out, this has happened to me before, also try to clean the catalyst maybe the butane is not flowing properly, hopefully this might help you, please let me know</p>
I never thought of removing the piece of the child safety, sounds like a really good idea! Sounds like an extra work for my Dremel 400 XPR, jeje thank you petercd for the tip<br><br>And thank you MsSweetSatisfaction for the comment
<p>Thanks, its always nice to see the insides. I got annoyed by the blue child safety piece and cut it off, my youngest is 23yr, so not really something I'm worried about. :) </p>
<p>Nicely explained! Thanks for sharing your knowledge.</p>

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