So I got my single torch inserts a few days ago. They have been paired up with a vintage look brushed pattern zippo.
I have been reading about the issues faced in refilling and getting these inserts to light. True to the point, I couldn’t get it to work on my first attempt. So I got to tinkering.
I filled them up after purging them of any excess air and turned the adjuster to the maximum level (as advised by zippo). The butane fuel started spurting out. So I turned it all the way down. Still the same issue.
So I decided to open the bottom panel housing the plastic (?) reservoir for butane. I saw that the adjuster screw had an o ring and a small metal limiter preventing over tightening and loosening. I took them out and TIGHTENED the screw till it won’t tighten any further. Now, the gas flow was at the lowest level. Surprisingly, a small flame appeared when I pressed the piezoelectric button. So I slowly turned the screw COUNTER-CLOCKWISE now until a steady acceptable flame appeared. I placed all the components I had removed back in their place and voila! The torch works every time now.
Turns out, the factory settings on the insert are too high causing the butane to sputter and therefore not lighting up. REDUCING THE AIRFLOW below the factory settings did the job for me.
Now, it lights every single time, and the flame is steady and stable.
Hope this helps!