Originally Posted by LarryP
As a matter of fact, we tested the simple on/off switches designed by other companies and in one case found it to lose 25% of the power from the battery by the time the current reached the liner.
Not sure about 25% loss, but there is (was) in my on/off switch.
History of my on/off switch:
4 or 5 winters of light usage with jacket liner only. By the time it got cold enough, we had snow/ice on ground in NY, and I'd put the bike up for the winter.
1 winter of moderate usage, with jacket liner and gloves. Downtime due to nail in tire, and trouble locating replacement for reasonable cost.
1 winter of heavy usage, with jacket liner, pant liner and gloves.
3/4 winter of heavy usage, with jacket liner, pant liner, gloves and insoles. Switch lasted for 31 of 35 mile trip to work today. It smells funny now, and was stuck in the ON position until I gave it a little shake, heard something loose inside. Outside temperature was right around freezing, and will probably be only a few degrees warmer for ride home.
For a switch to over-heat like this means it was eating some of the power that should have gone to my gear. 25%? for a brand new switch, I would doubt. But a switch that's been used for a few years, very possible. I did pry the switch open to find melted plastic.
Now to contemplate $15 for a new switch, or $100 more for controller. Also about due for new tires, so that may sway my decision.