Broken Compressor Regulator

[EMD360]

I hope its OK to post this in Class C's. It is a followup to the air compressor discussions on this forum. I've posted before that I bought the small form factor DeWalt 135 PSI compressor to take in the RV. I had returned the leaky Black and Decker for the DeWalt--only to find they are the exact same machine.

It is only about 2 years old and I've used it literally a handful of times. I just took it out this week as I'm cleaning up the RV for winter. I tried to use it on an inside project and it was leaking like crazy. Pretty disappointing to have a broken $120 compressor. Now this model costs $154 on Amazon.

Turns out the regulator is "built to break" in these things and there is no replacement kit! I could buy a whole new manifold for $55, but not the little plastic parts that go in the regulator.


Following instruction on the Internet, I took it all apart and greased the o-rings but it still leaked. I tried using pipe dope on the little screw in piece, but it still leaked. I tried leaving the cap off (no pressure on the spring) and it built up pressure but didn't fill the tank. Pushing down on the stem piece let out a stream of air.

I didn't know how the regulator actually worked, so I looked up a lot of information about them and learned a bit. Actually cool little devices. My dad used to refer to poppets and never really understood what he was talking about--now I know.

Here is the best illustration that I found.

So I thought I could just plug the middle of the stem part and block the air--I used some sikaflex caulk that I had out for the RV and let it dry a day or two before I tried it. Seemed to fix the leak too.

I'm not sure how much air pressure the caulk can take before it starts to leak again. I can't imagine how many of these are ending up in landfills due to a tiny plastic piece that cannot be replaced. Who designed this thing? Who decided not to offer the regulator kit as a $5 replacement?

[EMD360]

Interesting responses--thanks so much. I am a directions reader so do open the air release after each use.
I've checked out several of the regulators online and I'm wondering if a similar plastic model for a Black and Decker or DeWalt would have the same inside parts. That would be better than trying to rebuild the manifold which I could see doing with some pipe tees etc. Everything screws into this manifold except the regulator which is built into the manifold.
I have a larger Harbor Freight compressor which is one reason I have not used the smaller one very often. I really don't want to trash this one--it is practically brand new.
This is kind of a rant too regarding the lack of individual inside parts for this regulator. Since the regulator itself is not replaceable. Would be a pretty inexpensive kit and obviously they break often. In the meantime I CAN use the compressor with the plugged stem piece. Just don't feel like I can rely on it in the field especially.

[Raymon]

One mistake many people make is not bleeding all the air out of the holding tank between uses of the compressor. The compression of moist air creates condensation in the compressor's holding tank. Failure to bleed out the air will cause regulators and pressure safety switches to corrode. A malfunctioning safety switch can be very dangerous. Hope this helps.

Ray

[klutchdust]

I use Mc Master Carr or Grainger. If you look at their online catalogs you can get some good ideas. The black twist type regulators tend to fail. I have found the ones

that are more cone like with the metal twist adjustment to be more reliable. I have one from HF that is over 5 years old and works great.

[Alfred622]

Pick one up from Harbor Freight or check eBay - they have many different styles.

[DrewE]

You could probably assemble the equivalent of the manifold and regulator assembly from bits and pieces for less than $55, I would imagine. Regulators are available lots of places, including the typical big box stores, places like tractor supply, or various online/mail order places.

I might see about using this regulator and some tees or crosses and nipples and such like bits....