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This guide will show you how to replace the felt pad and cotton inside any model of a Zippo lighter. Use this guide when you feel like your lighter has shorter fuel life than it had before. Replacing the cotton and the felt pad helps with evaporation and fuel flow, and it provides a longer fuel life. Try to replace the cotton every four months if you use your Zippo as your daily lighter.
Before getting started, purchase a felt pad and cotton pack originally made by Zippo.
If you have fueled your lighter with lighter fluid recently, do not use your lighter for a week and let the cotton absorb all the fuel. Therefore, when you want to do the replacement it will be dry.
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Open the lid of the lighter.
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Hold the bottom of the lighter’s case and pull out the metal container.
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Set the case aside for now.
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Turn the metal container upside down with the bottom facing you.
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Loosen the screw with a flathead screwdriver.
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Remove the screw with the spring and the flint attached to it.
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Lift the felt pad up and out of the metal container using a pair of tweezers.
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Use a pair of tweezers to remove the old cotton from the inside.
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Throw the old felt and cotton in the garbage.
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Use a pair of tweezers to push each cotton piece on top of the wick inside the metal container. Make sure the cotton pieces cover all the sides.
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Use a pair of tweezers to place the new felt pad on top of the cotton pieces.
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Replace the flint and screw it back into place using a flathead screwdriver.
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Refuel your lighter, put the metal container back inside the case, and test out the lighter.
When you repack a Zippo you actually want to make sure that you snake the wick in between every piece of cotton until the wit comes all the way to the bottom of the metal case but you want to be careful not to pinch the wick at any point especially up near the chimney where it comes out to be lit. Let the wick should snag all the way through the metal case to ensure it absorbs all the liquid from all the cotton. It will last a whole lot longer between refills.
If you want to know the very best way to repack the cotton in your Zippo I would watch this video from this guy who really knows his stuff when it comes to Zippo lighters.
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How do you put a wick in zippo when there is none?
