Joseph:
> Has anyone tried refilling an empty old style canister?
I do it all the time
> I am thinking, If you put the empty in the freezer to lower any residual gas pressure
Exactly how to do it, then have a liquid feed from your fuel source.
> then use a butane lighter refill can with the right adapter to open the valve and fill as much fuel as it will accept.
"the right adapter" being the operative term
Except a small container like a lighter refiller is usually more expensive than a larger container. Table-top butane stove canisters, often sold in Asian markets for table-top cooking can be a cheaper source of butane – cheaper than BPing canisters and can work if you don't need low-temperature performance.
> It won't take as much fuel as a new canister, but it might hold enogh for a meal or two.
Well, the big problem is actually the opposite. A cold container can hold MORE fuel than is safe. Liquid hydrocarbon fuels expand and contract with temperature changes MUCH more than water does. If you get too much fuel in the canister and then it warms in a car trunk, the sun, etc, while still quite full, the pressure is no longer limited by its vapor pressure and the canister will rupture. This is why I record a full weight on every canister type/make/model I use so I never refill beyond that limit. e.g. if it came with 8 ounces of butane and weighed 13 ounces full, I always reweigh it after filling and burn off or vent off any excess fuel.
Refilling / transferring between canisters is pretty tricky to do safely. I'm cool with Jim doing it. He doesn't worry about me. But there's a lot of engineering, plumbing, and chemical concepts to factor in and I admit to learning some things during exciting moments that lasted a fraction of a second.