Aqualung - Calypso Regulator rebuild suggestions

[mmcdanie]

I've come into an old Aqualung Calypso. The 2nd stage leaks air when pressurised and I'm sure this thing has not been in the water or serviced since the late 70s. I'd like to use the reg and an old 72 steel that I also got, that I'm going to have tested, as equipment I'd keep on my boat to do minor bottom work on the boat. Any thoughts on special things I might ask a technician to do to the regulator when rebuilding both stages? Can it be rebuilt?
Thanks

 

[herman]

Not likely you will find a shop tech that will service it since it is no longer supported by AL- the liability thing. However, service kits (aftermarket) are available from Vintage Double Hose and it is easy to service with no special tools other than an IP gauge, why not just do it yourself.

 

[mmcdanie]

Found out that VDH has the 2nd stage kit, which I ordered, and the repair manual which I downloaded. They did not have a kit for the Calypso 1st (1023-00)stage but stated they may have a seat for it if I need it. With the manual and the kit, I think I will give it a try. Thanks for the advice.

 

[herman]

What was I reading???? For whatever reason I got it in my head it was a different reg, anyway, the good news is that HP seat if reversable so be careful taking it out and you can use the opposite side. Check the IP first before doing anything to detemine if it's the first or second stage giving you problems. If it's the first, odds are it's not the seat but one of the orings. I would replace the orings and leave the seat on the same side first, it it still leaks then flip it.

 

[mmcdanie]

I've rebuilt the 2nd stage with a kit from VDH and it is working great. The seat in the 2nd was a bit worn and the kit came with a replacement. I've found a kit for the Calypso 1st stage and will be working on it next week. The HP seat looks great but the diaphragm was shot as were some of the o rings. The original factory intermediate pressure setting was 120psi but I've read a few notes, including one hand written in the manual I downloaded, that say to set the IP to 135psi.

 

[herman]

Diaphragm??? Back up a minute...which Calypso do you have? There are 3 basic versions, the old original (balanced diaphragm) the mid model ( balanced piston) and the later unbalanced piston reg. I assumed you had the more common middle one....you know what assuming does to you. Forget the flipping the seat suggestion, that only works on the mid version...I wish USD would not use the name on different regs. That manual gets around...I have a copy too. Odds are the diaphragm from any other USD diaphragm reg will work. (Bryan sells them)

 

[mmcdanie]

The old original most likely, one lp and one hp, part number 1023-00. Thanks for suggesting to do it myself. I've learned a lot so far with the disassembly of the 1st and 2nd and the assembly of the 2nd. The manual is great because it has the steps and the exploded views.

 

[John C. Ratliff]

mmcdanie, is it this Calypso (the original)?


This is the first generation Calypso.

Or, does the regulator look like this:

This was the third generation. This one is a balanced piston first stage. From the patent, this is what the third generation innards looks like:


The second generation was a combination of the first stage of the first generation (with a different hose attachment) and the third generation second second stage (with a smaller exhalation valve).

John

 

[mmcdanie]

Finished the first and second stage rebuilds and did a pool test. Tested great. I had not replaced the high pressure hose, so when I was in the pool I noticed that the HP hose was actually swetting air, small bubbles all along the lenght of it. I have never seen anything like that before. I have new LP and HP hoses on the way.

 

[Luis H]

I don't know if you realize that the exhaust T on you second stage is up-side-down. Some people actually used to install it like that intentionally, but it was designed to be 180 degrees of what your pictures show.

You will notice a slight chin rest depression when you install it correctly.

Some divers used to think that by pointing the exhaust down it would get the bubbles further away, but it doesn't. And then there were other that just thought it was cool to mount it up-side-down to be different... and that is not a bad reason... :cool2:

I personally think it looks better the way it was intended...