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Electrode End Caps And Fit

Not all end caps are alike.  This can be a bit frustrating when dealing with violet wands, when accounting for proper fit.  All violet wands and similar devices hold electrodes and accessories in place inside the wand with a friction grip.  Push in too far, the electrode jams, pulling off the endcap when you go to remove it.  Push in not enough, and your electrode isn’t held tightly.  Your collet may stretch or splay from forcing electrodes too deep, and not fit properly.  So this article discusses all the surrounding issues with different endcaps, PLUS how to tweak and fine tune for proper, frustration-free fit.

A lot of this information about endcaps applies to all Direct accessories you plug into your wand, such as Body Contact Cables as well.

 

 

 

Every violet wand producer uses different end caps on their electrodes and accessories, partly out of a desire to mark their accessories as different, and partly depending upon how they balance the cost versus the quality of the materials.

Most producers in the US produce electrode/accessory end caps to American Standard Size, 7/16″.  Mjolnir Violet Wands all have universal collets, so those violet wands have no fit issues, as they accept electrodes of all sizes.  However, they are the only ones that have universal collets. Among manufacturers, there is a +/- variance in exact measurement in violet wand collets, and there is also a +/- manufacturing tolerance range in endcaps.  This can be because endcaps can go out of round during their mass manufacture, or they can have slight individual differences like ours that are pressed by hand individually with a 12 ton hydraulic press.  Being a hair off is certainly an acceptable tolerance, but it can be frustrating if most of your electrodes end caps fit your wand perfectly and one is just a hair to big or too small.

Your wand collet will accept a small range of manufacturing variance on 7/16″ anyway, since wand collets hold by a friction grip, and get narrower toward their base as you insert an electrode.  This means that endcaps toward the – (minus) end of the +/- variance, will fit deeper, and endcaps toward the + (plus) end of the +/- variance will fit shallower.  Do not panic if metal of the endcap is showing outside of your wand’s nosecone when you insert it!  Insert wand electrodes and accessories only till they are held securely, do not push or jam them in.

The endcaps that are the kindest on your collet will have a rounded end, which allows a gentle but firm friction grip of your collet.  Straight cut aluminum tube is much less expensive since it can be cut by hand and doesn’t require machining or hydraulic pressing, but the straight edge increases the risk of stretching your collet when inserting too far.

The green line in the diagram above shows the relative depth you should be using for each type of electrode endcap.  It is alright for metal to show!

Forcing an electrode or accessory into the wand, can crack the seal on your electrode, allowing gas to escape.  It can pull the endcap right off the electrode.  It can damage your collet.  So insert your electrode with a steady but light pressure.  Do not twist, and do NOT FORCE.  Just push them in gently until they are held, and then stop.

OUR electrodes are under lifetime warranty against losing their seal or their gas or their endcap.  The quality materials and processes we use mean it is unlikely that forcing an electrode or accessory into your wand will damage the electrode or accessory.  But if you have the lesser quality import electrodes, you will damage your electrode by pushing it into the wand too hard.

You may have other problems with foreign import electrodes.  One of them is fit as they can be slightly smaller than American made for American standard size 7/16″.  In the video below I show you how to deal with an electrode that just doesn’t want to stay in your wand.

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