How to Repair a Dremel VersaTip's Igniter

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.