Vintage Lighter Restoration: How to Fix a Flint Jam

One of the most common issues in vintage lighter restoration is the dreaded flint jam. If your lighter isn’t sparking, there’s a good chance an old flint has broken down inside the tube. But why does this happen—and how do you fix it?

What Causes Flints Jam?

Flints are made from ferrocerium, a metal alloy that contains rare earth elements. Over time, when exposed to oxygen and moisture, these flints begin to deteriorate. They either break down into powdery dust or fuse to the inner walls of the flint tube, blocking any new flint you insert from making contact with the file wheel.

How to Tell If You Have a Flint Jam

Here are three reliable ways to diagnose a flint jam in your lighter:

1. Dusty debris – When removing the flint spring, you notice grayish dust falling out, and the spring feels difficult to remove. Infact, sometimes you need really give it a tug to remove it.

   
   

Personally, I skip the second method and go straight to the third—using a blower avoids the risk of jamming another flint in the process. (And yeah...that's happened)

1. New flint won’t connect – A fresh flint is hard to tighten, and you see no spark or contact with the wheel.

2. No air flow – Using a small handheld blower, you try sending a puff of air through the flint tube. If nothing comes out, it’s blocked.

How to Clear a Flint Jam

Once you’ve confirmed a jam, it’s time to clear it. The best method depends on your lighter’s design and your comfort level.

From the Bottom of the Tube

• Poke Method: (For curved or straight tubes) Curved tubes are the most challenging, as you can’t always push a jam through.  Using a thick, stiff wire—something stronger than a paperclip, like 14-gauge smooth wire, file one end to a point, add a drop of alcohol to help loosen debris, and carefully work the jam out. Warning: this may take time and patience. You make also need to scrape the sides for remaining bits.

• Drill method: For straight tubes, you can also use a 3/32” x 6” drill bit. Go slowly, keep a finger on the file wheel, and stop once you feel vibration against the wheel.

From the Top of the Tube

Taking the lighter apart allows you to attack the jam directly and clean flint deposits from the file wheel. The benefit is precision and full restoration. The risk? If you’re not experienced, you may struggle to reassemble the lighter. Always weigh the risk vs. reward.

Pictured is an example of what a jam looks like from the top, how'd you'd drill from the top, and the guts a standard, Japanese pistol lighter with a very curved flint tube. Note, that the greater the curve, the more likely you're taking it apart. (and that screw on the pistol is lefty tighty, right loosy)

When to Call for Professional Help

Sometimes it’s smarter to leave flint jam removal to an experienced restorer.

Contact us if:

• You don’t want to invest in specialty tools for just one lighter.

• The lighter has sentimental value, and you want it restored safely.

• Your lighter doesn’t work, and you’re unsure whether the problem is a flint jam or something else.

  
  

👉 Need help restoring your vintage lighter? Reach out for a quote—most repairs are under $40 plus shipping.