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bangladessional dive professional
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Discussion Starter #1
Hey
Im in the middle of servicing my FSR first stage and the balance plug is well and truely stuck. so much so that the allen key hole is going from hexagonal to round. So, assuming i can write off the plug and get a new one, how do i get it out?

Im in remote indonesia - its a couple of days journey back to a proper dive shop so getting it for a 'real' service isnt much of an option at all but i should be able to get parts sent over.

any ideas greatly appreciated

cheers
 

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do you mean the metal one on the outside bottom of the reg? the only way i can think is try to cut a straight line into it and use a flatblade screwdriver to try and remove it.

dont cut the body of the reg though as i would hate to think what would happen if you put a weakspot into the HP stage of that reg.
 

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bangladessional dive professional
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Discussion Starter #3
yep thats the one. i was thinking something along the lines of that - how about a couple of holes and jam some needlenose pliers in and twist?
 

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You'll bend the pliers.
Do the same, but use a bar or spanner close to the reg to push the pliers tips, not the pliers handle.
 

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A good method, if you can find a torx bit is to hammer it into the hole that has been rounded off, so that it is jammed in solidly, works far better than trying to cut a slot across the top. I have extracted some truly jammed bits this way.

Charlie
 

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A good method, if you can find a torx bit is to hammer it into the hole that has been rounded off, so that it is jammed in solidly, works far better than trying to cut a slot across the top. I have extracted some truly jammed bits this way.
Class. How about dynamite? :D
 

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Making God laugh...
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Obviously, this wont help with the immediate problem, but having just 10 mins ago completed an Aqualung Technicians course can I ask, when you last cleaned/serviced/looked at them, did you use silicone grease as the lube when you put em all back together?

The reason being we have just heard a lot of horror stories as to why silicone grease should not be used in regs as it dries up and things start to weld together after a period of time, wondered if this was the case with yours?

Regards

Steve
 

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don't know if that would help as the bit that is stuck has a O ring this side of the threads, unless you wanted to flood the reg with it on the off chance.
 

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It seemed like a good idea at the time...
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I hate to say it - I had one in a similar situation a while back and had to have it drilled out in the end.
 

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- .... . -.. .. ...- . ..-. --- .-. ..- --
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do you mean the metal one on the outside bottom of the reg? the only way i can think is try to cut a straight line into it and use a flatblade screwdriver to try and remove it.

dont cut the body of the reg though as i would hate to think what would happen if you put a weakspot into the HP stage of that reg.
Has the same problem with a DS4, which wouldn't shift. Having boiled the bastard in 50% vinegar for a period, the hex recess rounded off at about 1.5 Nm more than the suggested torque for doing it up. I cut a slot across it, then bent two screwdrivers and broke a multi-tool blade trying to turn it. (You may have guessed that I don't like to lose!)

Ultimately, I cut a broader slot across it and put a wood bit (22mm, IIRC) across the slot as a lever, then tapped the other end of the bit with a rubber mallet till it turned.

Mission accomplished! Albeit with a bent wood bit also!

Despite the above abuse, the reg worked fine once serviced. I did, however, rotate it off my right post after I slashed my hand on the edge of the slot while doing a shut-down. I've now poured some molten wax into the slot as a short-term measure, though will need to replace that with something more permanent unless I can source a replacement part.

Iain
 

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bangladessional dive professional
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133 Posts
Discussion Starter #16
Obviously, this wont help with the immediate problem, but having just 10 mins ago completed an Aqualung Technicians course can I ask, when you last cleaned/serviced/looked at them, did you use silicone grease as the lube when you put em all back together?

The reason being we have just heard a lot of horror stories as to why silicone grease should not be used in regs as it dries up and things start to weld together after a period of time, wondered if this was the case with yours?

Regards

Steve
errrm......yes.......oooops

anything else i shouldnt do next time?
 

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Has the same problem with a DS4, which wouldn't shift. Having boiled the bastard in 50% vinegar for a period, the hex recess rounded off at about 1.5 Nm more than the suggested torque for doing it up. I cut a slot across it, then bent two screwdrivers and broke a multi-tool blade trying to turn it. (You may have guessed that I don't like to lose!)

Ultimately, I cut a broader slot across it and put a wood bit (22mm, IIRC) across the slot as a lever, then tapped the other end of the bit with a rubber mallet till it turned.

Mission accomplished! Albeit with a bent wood bit also!

Iain
I hope you don't take such a vigorous approach in your workplace!
 

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Just remember with all the hammering, cutting, drilling discussions above, that the body of the reg is chromed brass, i.e. soft as butter.

If you really twat it with things and hammer on it you will eventually damage it.

Personally, I'd leave the plug where it is, and service the reg without taking it out. Unless it leaks I don't see the issue. This obviously assumes you don't need the plug out to reconfigure the regs at any stage.

Digs.
 
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