Bizarre CO2 leak fixed, most of you have likely never seen this (w/ pics + video)

[7ways]

I have been in the beer business for a while and I fix gas leaks all the time. I take pride in getting it done quickly and efficiently. So it was infinitely frustrating for me to have one in my personal kegerator and not be able to figure it out for months! So tonight rather than damn near climb into my kegerator for the 10th time, I unscrewed the regulator panel and yanked it out. As I was once again swabbing the threads and release valves, I flipped it upside down and spilled leak detector on the back of the regulator. Sure enough, bubbles started emerging from the SOLID back side of the regulator!!! Pics and video should explain how f'd up this is.

1st pic - what I'm working with, 5 secondary regulators flipped over

2nd pic - a close up of one of the two leakers

3rd - same close up, but the green dots mark the beginning and end of a fissure so small I had to take my glasses off to see it! The leak is occurring where the left green dot is, right in the middle of that engraved H!!! This happened in the exact same spot on two of my five regulators, so it is not a coincedence.

Video of this ridiculous leak: https://www.youtube.com/watch?v=fEIEuwXiFh0

I swear, just when you think you have seen it all...

 

[CadiBrewer]

I once added on a room to my house. When I ran the gas piping for the addition, I was required by the inspector to fill the gas pipe with pressurized air and leave it over night with a pressure gauge on it to ensure that it held pressure. I pumped it up, left it and came back to a lower pressure reading. So I sprayed soap on every joint but couldn't find any leaks, so I re-tightened all of the joints. I ended up doing this three times, using new thread sealant tape and other sealing compounds to no avail. On the fourth day, I called my friend who was a plumber. He listened to my story, went straight to the gauge, turned it over and found a fissure almost exactly like the one you have. I was embarrassed and livid at the same time. Too bad RDWHAHB doesn't work on everything.

 

[7ways]

Thanks Cadi, it's good not to be alone.

I'm wondering now if I can put JB weld or something else over the crack to stop the leak?

 

[MaxStout]

I once added on a room to my house. When I ran the gas piping for the addition, I was required by the inspector to fill the gas pipe with pressurized air and leave it over night with a pressure gauge on it to ensure that it held pressure. I pumped it up, left it and came back to a lower pressure reading. So I sprayed soap on every joint but couldn't find any leaks, so I re-tightened all of the joints. I ended up doing this three times, using new thread sealant tape and other sealing compounds to no avail. On the fourth day, I called my friend who was a plumber. He listened to my story, went straight to the gauge, turned it over and found a fissure almost exactly like the one you have. I was embarrassed and livid at the same time. Too bad RDWHAHB doesn't work on everything.

Something about that cheap, cast brass/bronze used for some gas and plumbing fittings. I have already replaced both spigots in my laundry drain basin, both hose bibs outside, and even the main water shutoff valve. In each case, the part had developed a tiny crack in the casting and little streams of water were soon jetting out. Luckily I haven't had any problems with gas fittings...yet. And my house isn't that old.

 

[WileECoyote]

Thanks Cadi, it's good not to be alone.

I'm wondering now if I can put JB weld or something else over the crack to stop the leak?

How long have you had them, thats a manufacture defect for sure, the manufacture should stand behind it, even if you have had your regulators for a long time ill bet if you call or email the manufacture they just might help you out.

If they wont help you JB Weld is worth a try, it is amazing stuff.

Cheers

 

[Yuri_Rage]

Looks to me like over tightening the fitting on that side may have caused a crack. JB Weld won't fix it. New regulators are likely required.

 

[JDGator]

looks like the fittings may have been overtightened. when working with soft metals you don't want to over due it. adding the tape makes the fitting larger then the intended thread size.

 

[JDGator]

Looks to me like over tightening the fitting on that side may have caused a crack. JB Weld won't fix it. New regulators are likely required.

geez, you beat me too it.

 

[aeviaanah]

I bet u can braze it- brazing is like soldering. Keep the heat to a minimum as to not damage the internal workings.

 

[TallDan]

Looks to me like over tightening the fitting on that side may have caused a crack. JB Weld won't fix it. New regulators are likely required.

Is this the general approach for regulators? I have a primary that is leaking through the threads where the connection to the co2 tank threads into the regulator body. I tried to tighten or loosen that connection, but there appears to be some corrosion on it, and I can't get it to budge. My thought was to put some tape on that connection, but I'm guessing it's a lost cause and just time for a new one. Thoughts?

 

[7ways]

How long have you had them, thats a manufacture defect for sure, the manufacture should stand behind it, even if you have had your regulators for a long time ill bet if you call or email the manufacture they just might help you out.

If they wont help you JB Weld is worth a try, it is amazing stuff.

Cheers

I have had it for almost 2 years. I am thinking of giving them a call.

 

[7ways]

Looks to me like over tightening the fitting on that side may have caused a crack. JB Weld won't fix it. New regulators are likely required.

Good point about the over tightening. It seems like a combination of that and a defect since the leak is occurring on the exact same square millimeter of space on two consecutive regulators.

I did not screw these together btw, it came assembled like this from kegconnection.com

 

[7ways]

Is this the general approach for regulators? I have a primary that is leaking through the threads where the connection to the co2 tank threads into the regulator body. I tried to tighten or loosen that connection, but there appears to be some corrosion on it, and I can't get it to budge. My thought was to put some tape on that connection, but I'm guessing it's a lost cause and just time for a new one. Thoughts?

Do you know if you have a nylon gasket or fixed rubber o-ring inside that connection? If you can get it apart that is the first thing to look at. Keep at that hex nut, I have had some tanks and regulators that were screwed together so tight it took two people to get them apart, one person with a pipe wrench and another with a mallet. I'm not saying you should start bashing up your equipment, but don't give up yet.

 

[TallDan]

Do you know if you have a nylon gasket or fixed rubber o-ring inside that connection? If you can get it apart that is the first thing to look at. Keep at that hex nut, I have had some tanks and regulators that were screwed together so tight it took two people to get them apart, one person with a pipe wrench and another with a mallet. I'm not saying you should start bashing up your equipment, but don't give up yet.

No clue what's in there. I've already been a little more aggressive with than i probably should be, but if i can't get it fixed, i'm going to need a new regulator anyway, so why not? I may beat on it more tonight, and if i can't get it, just pick up a new regulator from the LHBS.

 

[IslandLizard]

No clue what's in there. I've already been a little more aggressive with than i probably should be, but if i can't get it fixed, i'm going to need a new regulator anyway, so why not? I may beat on it more tonight, and if i can't get it, just pick up a new regulator from the LHBS.

Have you tried spraying it with WD40? Or a (teflon) spray lubricant?

You'll have to clean it well afterwards so your beer doesn't taste like it.

 

[zachattack]

Is this the general approach for regulators? I have a primary that is leaking through the threads where the connection to the co2 tank threads into the regulator body. I tried to tighten or loosen that connection, but there appears to be some corrosion on it, and I can't get it to budge. My thought was to put some tape on that connection, but I'm guessing it's a lost cause and just time for a new one. Thoughts?

Mine started leaking from the same spot after a year. You can get it off with some muscle, chances are there's a good layer of pipe dope at the joint. Remember some regulator manufacturers (like Taprite) use left handed threads! A big pipe wrench should be able to get the bastard off there, then go to your LHBS and buy a new nipple for like $4, put some PTFE tape on it, put it back in and you're good to go.

 

[Stealthcruiser]

I concur with the over tightening theory, and it just took it some time for the crack to migrate enough to start leaking.

I'm guessing, the threads are "NPT", plus during manufacturing, as a cost cutting measure, they elected not to "break" any of the sharp edges created during the machining processes, ( on the regulator body, the female threads, the stamping on the back of the body), and that threaded opening into the body is prolly' pretty close to the back of the body, yes?

Those "un-broken" edges will create stress risers, and with so much going on in such a small space, torquing down the fitting killed it!

New regulator or regulator body are in order.

Unless ya' wanna' completely gut the regulator, "V" out the crack a little, and braze it up!

I got a dollar says the JB Weld won't last, ( although I do love the stuff!)

 

[7ways]

I concur with the over tightening theory, and it just took it some time for the crack to migrate enough to start leaking.

I'm guessing, the threads are "NPT", plus during manufacturing, as a cost cutting measure, they elected not to "break" any of the sharp edges created during the machining processes, ( on the regulator body, the female threads, the stamping on the back of the body), and that threaded opening into the body is prolly' pretty close to the back of the body, yes?

Those "un-broken" edges will create stress risers, and with so much going on in such a small space, torquing down the fitting killed it!

New regulator or regulator body are in order.

Unless ya' wanna' completely gut the regulator, "V" out the crack a little, and braze it up!

I got a dollar says the JB Weld won't last, ( although I do love the stuff!)

JB is the cheapest and easiest by far, so I will start there on one of the cracked regulators. I'll see your dollar and raise you two bits!

I can solder pretty well, could I try that instead of brazing? Brazing requires more equipment than I have access to. Probably not worth the time, $, and effort.

 

[Stealthcruiser]

Just remember, if it don't work, ya' gotta' remove all that crap before you can try another route.........

Sure, you can try soldering........Clean the hell out of it, and use some good, washable, (water soluble), flux.