pescador775:The 109 brass seconds were good regs by 70's stds. However, the 250HP is a much better breather and, most important, the mouthpiece is light. The 109 causes jaw fatigue. There was a tendency for the adjustment knob of the brass second to bind with salt corrosion and the unbalanced poppet needed frequent adjustment. However, with yearly maintenance, the 109 was extremely simple and reliable, very rugged. The 250HP is quite complex and plastics are always questionable in severe environments like diving. Give a little, get a little.
Light mouthpiece - Personally in my experience a well designed mouth piece (the rubber part that actually goes in your mouth) and a properly sized and routed LP hose both have a lot more to do with eliminating jaw fatigue than the weight of the second stage itself.
I have never personally had a problem with jaw fatigue on a 109 second stage but light weight is a big selling point for phenolic resin/graphite resin cases, so it is obviously a good thing from a marketing perspective, even if it is not a major concern in the water.
One other thing about the light weight resin cases, a graphite resin case with 100 dives on it is normally extremely scratched and not at all attractive. In contrast my 20 year old chrome plated Balanced Adjustable second stages all have an even patina of very faint scatches but the chrome is still intact and they still look very attractive and not nearly as old and worn as the average 3 to 5 year old G250 which normally look like they have been mauled by a very big and angry wire brush.
Corroded knobs - I agree the metal adjustment knobs could get sticky in the metal cased regs, but they had the same problem in the older G250s with the the plastic case and the metal air barrels. The same argument was used to move away from metal orifices. We do seem to agree that with good maintence it was not a problem though.
G250 HP =much better beather and unbalanced poppet (?) - The Adjustable had an unbalanced poppet but the Balanced Adjustable had a balanced flow through poppet design.
In fact the Balanced Adjustable's poppet assembly was used in the original G250 and the only performance advantage offerred by the G250 was the adjustable VIVA flow vane. For most divers who set it in the middle at a moderate viva setting and seldom touch it, it is not really an advantage at all. The newer poppet assemblies used in progressively more advanced versions of the G250 are also available for use in the Balanced Adjustable, so the performance advantage of the current G250 HP over the original balanced adjustable still bascially comes down to the viva adjustment. Give a lot, get a little.