Vaporesso Armour Ultra Review: Real World Testing of a Tough 100W DTL Kit

Hands-on performance notes, daily usability and honest impressions
I have been using the Vaporesso Armour Ultra solidly for a week, taking it everywhere I normally take my daily DTL kit. That means it came with me in the car for early morning runs, sat on a café table while I worked, and lived in my hoodie pocket during a few long dog walks where I usually forget my device is even there. Spoiler: you don’t forget this one. Not because of the weight, but because it feels like a tiny chunk of industrial equipment that also vapes brilliantly.

What I wanted to know going in was simple. Is the Armour Ultra just a flashy rugged box with a huge battery, or does it actually perform well enough to be a genuine all-day DTL companion? After a week, I can say it’s both. It hits hard, stays cool, handles high wattage without drama, and feels like I could use it as a doorstop without scratching it.

Key Points
5500mAh built-in battery that actually lasts
Up to 100W of power with Boost Mode
Paired with the 6ml iTank T for proper DTL performance
GTi Dual Mesh coils with consistent, long-lasting flavour
IP68, IP69K and MIL-STD-810H rugged protection
Top airflow tank that resists leaking
Very pocket safe with the physical lock slider
Ideal for high VG liquids

Specifications

Build Quality and Feel
This is one of the toughest devices I have ever handled. The metal frame feels like something from a toolkit, and the rubberised grip sections give it a satisfying shock-absorber feel. During the week, I accidentally knocked it off a workbench onto concrete. Nothing. Just a scuff that actually made it look better.

The 0.96-inch screen is bright, clean and easy enough to read in sunlight. The leatherette panel feels comfortable and gives you more grip when chain vaping. The physical lock slider is one of the most practical features. When it is in my pocket, I flip the slider and know nothing will fire or adjust accidentally.

It is heavier than compact pods, but for a DTL mod with a 5500mAh battery, it feels surprisingly balanced.

Coil Performance and Flavour Testing

GTi 0.2Ω Mesh Coil (60 to 75W)
This coil hits the proper warm DTL I like after lunch. I usually sit at around 65W, and the flavour stays strong and clear. Even thicker dessert liquids did not wash the coil out. Vapour density is impressive without feeling oversaturated.

GTi 0.4Ω Mesh Coil (50 to 60W)
This became my “walking the dog” coil because it runs cooler and sips less battery. Flavour is still clean and consistent. The coil actually surprised me with how long it held flavour. I got through multiple refills without any sign of dullness.

Heat and chain vaping behaviour
One of the biggest standouts is how cool the mod stays. I chain-vaped both coils on purpose to see if the chassis warmed up. It barely changed temperature. The iTank T itself stayed stable too, probably thanks to the top airflow design.

Airflow and Draw Accuracy
I generally prefer bottom airflow for flavour, but the iTank T’s top airflow is well-tuned. Fully open gives a smooth, slightly airy draw without any whistling. Closing it down gives a tighter DTL inhale with more resistance that suits dessert flavours nicely.

The airflow dial is smooth, with enough tension that it does not move in pockets, yet it adjusts easily in hand.

Battery Life and Charging Notes

The battery is absolutely the star here. A true 5500mAh internal pack means I ran it at 65W for most of the day and still had battery left after dinner. Only on days when I was testing multiple flavours and chain vaping did I need to recharge earlier.

Charging is quick, although the rated 2A seems optimistic. It still refilled in a reasonable time, though. The battery capacity is as good as advertised, which is rare for a built-in mod.

Ease of Use and Everyday Practicality

For a 100W mod, the Armour Ultra is surprisingly easy to live with. No leaks thanks to the top airflow. The fill system is simple: push the cap, fill, slide back. The fire button is big and clicky with zero rattle.

Walking around with it, the weight feels reassuring rather than overbearing. It sits nicely in one hand, and the rounded edges stop it from digging in.

I would change the menu naming. Boost, Pulse, Eco, etc. I get what Vaporesso is going for, but sometimes I just want simple wattage. Still, once set up, you rarely need to go back into the menu.

Comparison Table: Armour Ultra vs Zelos 3 vs Aegis Boost Pro 2
Here is how the Vaporesso Armour Ultra compares with two popular alternatives, based on factual device data.

Quick Summary of Comparison
Armour Ultra excels in battery life, durability and high-power DTL.
Zelos 3 is best for MTL and simple all-day vaping.
Aegis Boost Pro 2 suits outdoor DTL users who like replaceable batteries.

Problems, Annoyances and Surprises
Menu system names are more complex than needed
Charging rate is lower than the advertised speed
Slightly chunky compared with compact DTL kits
Top airflow sacrifices a touch of flavour intensity

Real World Testing Notes
Survived a concrete drop without visible damage
The battery genuinely lasts all day at mid-wattage
Never leaked during the entire testing period
GTi coils hold flavour through multiple refills
Lock slider is massively helpful for pocket carry
Tank stays cool even during heavy chain vaping
Airflow numbers help repeat settings more easily

FAQs: What Users Actually Want to Know

1. How long does the 5500mAh battery realistically last at different wattages?
In real use, I consistently got a full day at around 60 to 70W with the 0.2 ohm GTi coil. On lighter days, where I switched to the 0.4 ohm coil and kept it around 50 to 55W, the battery pushed into a second morning. The internal battery behaves more like a dual-battery mod than a single-cell because of the capacity.

2. How does the Armour Ultra feel to carry all day?
It is heavier than a pod mod, but the weight is balanced and comfortable. Once I got used to it, the weight felt reassuring, not inconvenient.

3. Does the rugged rating matter in real use?
Yes. I dropped it from pocket height onto concrete, and it took the hit without damage. The rugged design is not marketing fluff.

4. How good is the flavour compared with other DTL coil systems?
GTi coils deliver warm, dense flavour at their recommended wattages. Not the absolute strongest flavour on the market, but well above average for a kit tank.

5. How fast does it actually charge compared with the spec sheet?
It charges fast enough, but not at the full 9V/2A claim. Expect roughly two hours for a near-empty battery.

6. Does it get warm during chain vaping?
The tank warms slightly at high wattage, but the mod stays cool. Heat management is excellent.

7. How reliable is the lock slider?
Very. It never slipped once and instantly disables all buttons when engaged.

8. Is the top airflow worth the small flavour trade-off?
Absolutely, if you want leak prevention. Flavour stays strong, and the peace of mind is worth the small sacrifice.

Overall Take After a Full Week With It

After a week of solid use, I am confident saying the Armour Ultra, produced by Vaporesso, is one of the most reliable, hard-hitting and durable DTL kits I have used in a long time. The battery life alone sets it apart, but the build quality pushes it into a different category entirely. It is the kind of device you buy when you want something that performs consistently without needing gentle treatment.

If you want a rugged DTL mod with proper staying power and consistent flavour, this is an easy recommendation. Whether you work outdoors, travel often, or just want a kit you do not need to baby, the Armour Ultra will handle it.