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In this video, it is demonstrated how easy it is to refill the old and used Thermacell butane gas canisters that you can buy here:
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The instructions include how to take apart your old canister and 1. prepare them for refilling, removing the brass valve, and 2. the small valve, Thermacell has placed inside the cartridges to prevent you from refilling your canisters. Then it is shown how to select the best fitting to the inexpensive refueling bottle with new butane gas.
The trick in this DIY Thermacell hack is to use a pincers that doesn't destroy the O-ring that seals your mini-caniaters inside your Thermacell unit. It is also highlighted how to find a screw that fits perfectly with the second aluminium valve inside the canister so that it can be removed and discarded.
The modified Thermacell canisters are best marked as ‘modified’ so that you remember which ones you can refill. Only after removing the internal valve can you refill the Thermacell butane gas cartridges. Once you have modified your cartridges, you have expanded your use of your Thermacell unit, and you can start travelling with it, and it's empty canisters to any destination where you can only go by airlines. Empty and opened canisters are allowed on the airlines. The cartridges can then be filled at your adventure destination by only purchasing a cigarette butane gas tube and refill them outdoors.
If you smell a little bit of gas when you refill your cartridges, this is not more dangerous than filling a cigarette lighter. However, you are advised to have good ventilation in the room where you are working and not to inhale butane gas (same as when you fill a cigarette lighter).