Regulator balloon

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Cheers! Good luck - I'm sure it'll work out fine.
When the reg comes back, the secondary diaphragm should lie flat against the underlying pressure plate. If you feel any space, like you can bounce the dry chamber diaphragm against the plate, you can actually just fix it yourself:
Unscrew the black cap surrounding that diaphragm with the Sherwood logo. It should only be hand tight. The black rubber diaphragm should come out with the cap. Reinstall the cap/diaphragm assembly flat against the flat disc (pressure plate) underneath, by simply screwing it on hand tight. DON'T push hard on the plate, but smooth out any bubble as you screw on the retaining cap. Done.

@runsongas , we were both forgetful - the Schrader valve is in the SRB9110 Brut, not the SR1/2. The SR's have that tripod that sits against the piston head that uses ambient pressure to nudge the piston, assisting the spring. I think this failure must have been (as you said) a vent hole problem, or perhaps a HP seat oring issue.

@mrmiller , you have an elegant design there. Sherwood is ahead of the pack on this one. It's the ONLY dry sealed piston around anymore. After they fixed that little glitch with the SR1 second stage, the SR2 set is pretty awesome.
 
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