How To Refill ThermaCell® Butane Bottles We all know the virtues of one of the GREATEST invention for hunters since the bow & arrow, the ThermaCell® unit. Its ability to repel pesky mosquitos and gnats has fast become a hunting backpack mainstay. However the cost of the refills can become somewhat expensive. I found out that it is possible to refill the butane bottles just like refilling a butane cigar/cigarette lighter. Here are the steps to follow: Pictured is the unit, a purchased refill package and used butane bottles. In this picture you’ll notice the O-ring on the brass nipple. Be careful not to damage it during this process. Now you’ll have to pull the brass nipple out of the top of the bottle. A slight wiggle back and forth will release it while pulling. It is only pressed in, there is no glue to break free from. I like to use a pair of nippers but regular pliers will do just fine. Nipple removed Now that the nipple is out you have to remove the check valve. This is installed so you must buy the refill packs from ThermaCell®. The check valve is there to prevent refilling. To remove the check valve you need only to screw in a threaded object such as a drywall screw, hand drill (such as I have used) or a drill tap would work as well. Just don’t screw it in so hard and deep as to damage or expand the hole it’s inserted into. The check valve is also just pressed in, so a firm, steady pulling will pop it out. Check valve out All that is left to do on the bottle modification is to reinstall the brass nipple. Align the nipple back in the hole, firmly press it back in. I then turn it upside down and seat it with a firm push on the work surface until it “pops” in with an audible click. Your bottle should now look as if it just came out of a new pack just empty. The next item that you will need is a butane refill bottle with assorted tips. For this I went to my local fine cigar store. I bought a big can with assorted tips for $7.49. This will refill, I would guess at least 10-15 bottles. In the assortment of tips you will find one with a split end. That will be the one that fits best to refill the empty ThermaCell® bottle. Insert the refill can tip into the empty bottle tip and push firmly down. It is important to fill the bottle as pictured. Gas must flow from the refill can to the empty bottle. That’s all there is to it. After you get the proper tip you can buy any refill butane bottle. I suppose at this point I should put in some sort of disclaimer. This is modifying a combustible gas container. You will be doing this at your own risk. I have done this and had nothing but great results.
I didn't think you could get the repellent strips by themselves. I thought they came packaged with a gas refill also.
There are folks on AT that have figured out how to refill them also...crushed something up that I cannot remember but I seem to think it was the coil bug smoke things. They crushed it to a powder and soaked the pads in them.
I got interested looking at this thread so I did some investigating as to how to "refill" the pads. The guys on the other thread were using the bug coils because they contained the same concentration of allethrin as the pads did. Allethrin is a synthetic analog of the naturally occuring insecticide pyrethrin. Another synthetic analog of pyrethrin is permethrin, the same chemical that people on here have talked about soaking their clothes in, in order to ward of ticks. I don't endorse trying to attempt refilling the pads, but I don't think the idea isn't without its merit.
You can buy a gallon of 10% Permethrin from Tractor Supply for around $16.00 I think it was. Diluted in 1/2 it should last years. I haven't tried it as of yet.
This is a great post, but I won't be doing it. I've messed around with valves and seals in the past and trying something with anything flammable would not be something I'm willing to risk. I've seen nicked O-rings cause blown valves and dancing in flames 20 feet up in a tree is not my idea of a good time. I'm just afraid I'd mess something up.
