Switch cover bulge.

[Linedog]

This happened after a dive, opened the can and it went down.

[Linedog]

Brad should respond soon with full details on what happened, I just took the photo. Then we laughed and said all kinds of things.

[CaptnJack]

looks like batteries got wet and off-gassed

[fmerkel]

Outside the opportunity for jokes, I'd say you've over discharged the pack. This can lead to H2 production. The old UK lights had H2 scrubber pellets in them for that purpose. I doubt they are used anymore.
I'd check out the pack. You may have a cell or 2 going bad.

[bradmond]

Has less than 20 dives on it. I dove Cove 2 earlier that day and it didn't do that. Did this after our 1st dive @ Saltwater but not 2nd dive. Did it once before a couple weeks ago. It gave something to laugh at between dives. I have another battery so I'll use that one next time.

[bradmond]

It is dry inside with no signs of moisture and have never ran battery down, only a couple hours use before charging.

[Linedog]

Off gassing batteries was our first thought also.

[Nwbrewer]

Definitely offgassing battery. I wouldn't use that one anymore.

[Linedog]

I wonder if the switch condom was compromised.

[H20doctor]

this happens when you put a Hot fresh charged battery into your canister... right after it came off the charger and then you threw it into the canister...then went diving . Ive seen this many many times...could also be a battery getting warm during use, like others have stated Off gas..or I could be wrong .. batteries do weird things

[bradmond]

this battery was charged the day before and was used earlier in the day for a 1 hr dive, no bulbous switch. On the 2nd dive the switch reservoir tip was inflated but not after the 3rd dive.

[rsc3001]

quite the temperamental light switch cover it seems....brad do you notice it when you use the other battery?

[bradmond]

I haven't used the other one yet, bought for a spare so I'll use it next time.

[Dusty2]

Check the gland nuts and the switch cover to insure they haven't loosened up also make sure the battery cap is on securely. This can happen if the canister equalizes while at depth. When you return to the surface the can is pressurized and the only relief point is the boot. It can do this without allowing much water in but you will usually find a small amount of moisture in the can. clean and lube your o-rings and make sure the nuts and switch boot are tight and examine the switch boot very closely. A small pinhole at the top of the boot could be the problem. If you like you can get it back to me and I'll check it out.

[jeffgerritsen]

Brad,
Oh that's not good. Time for a new battery pack and switch boot!

Find a hammerhead soldering tip and you can make your own packs using a 60 watt soldering iron.

[bradmond]

thanks Dusty, I'll check it out and let you know.

[bradmond]

I agree Jeff, should replace boot, it was stretched out pretty good.

[Dusty2]

I agree Jeff, should replace boot, it was stretched out pretty good.

Yes but it didn't burst or loose pressure till the can was opened so that means it is not leaking. If it was damaged it would have failed.

[bradmond]

I think it would be best to have the manufacturer have a look at it.

Dusty, Are you available next Tues, Wed, or Thurs to check it out? I can bring to you, assuming your eyes are doing good after your surgery.

Brad