109 Restored

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Art Challacombe

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I just don't log dives
Aloha everyone,
I was given a Scubapro 109 second stage that was headed for the trash heap. Basically, the adjusting lever would stick in the up or down position. No springing back when pressed down. Try as I might, I could not get the lever to function properly. I tried various different levers, springs and poppets to no avail. Desperate, I got in touch of Couv and asked for his assistance. Being the great and knowledgeable guy that he is, Couv walked me through the possible problems and sent me a lot of technical information. After several emails, we both concluded that the square holes that hold the lever in the barrel may be rounded and worn and in need of filing them square again.

I thought okay, I have nothing to lose, so I purchased some mini files and proceeded file and clean out the rough spots as well as squaring the corners. Beware though, this procedure is not for the faint of heart. Filing these holes is a slow and meticulous process. There is no room for errors.

After finally smoothing out the lever holes and installing a second lever, success! The 109 now works as it is supposed to and will be spared the trash can. Thanks so much, Robert. You and the folks on this board are amazing.
 

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whaylonsmithers

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Great post thanks Art. Q - was the roundness of the holes visually obvious? I've got one I'm about to have a look at - doesn't stick but its never cracked easily either.
 

Art Challacombe

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Hi whaylonsmither - no, the holes are in the bottom corner of the barreI and damage is hard to see. It doesn’t seem to take much to hang up the lever. I only saw the problem areas by using a jewelers loupe and a flashlight. Getting into the corners is not easy either as there is little room to maneuver a regular sized mini file. The one I used was a small curved square file. The curve allows access to the holes without having to file at an angle, something you don’t want to do. As far as your issue with the cracking pressure, you might want to try a different lever. I switched to the later model with smaller feet and it’s working well.
 

Art Challacombe

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Hawaii
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I just don't log dives
The 109 is complete; new lever, new duro poppet, new orifice, new rubber diaphragm cover, new exhaust valve and new mouthpiece. Now, the only thing left to do is adjusting the cracking pressure and water testing. Once it’s done, it will be connected up to my MK5 as a safe second and ready to hit the Pacific.
 

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whaylonsmithers

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Hi whaylonsmither - no, the holes are in the bottom corner of the barreI and damage is hard to see. It doesn’t seem to take much to hang up the lever. I only saw the problem areas by using a jewelers loupe and a flashlight. Getting into the corners is not easy either as there is little room to maneuver a regular sized mini file. The one I used was a small curved square file. The curve allows access to the holes without having to file at an angle, something you don’t want to do. As far as your issue with the cracking pressure, you might want to try a different lever. I switched to the later model with smaller feet and it’s working well.
Yep, I'm starting with the lever, spring, balance chamber and diaphragm in approximate order of expense. I sincerely hope it doesn't come down to my "delicate" touch on the barrel holes.
 
https://www.shearwater.com/products/swift/

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