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Is it leaking from the ambient ports?
If it is, I can't hear it. I cannot submerge it to check.
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Is it leaking from the ambient ports?
You don't need to turn the tank off. Just "breathe" off the reg to cycle the piston.
If it is, I can't hear it. I cannot submerge it to check.
Guru said, "Is it leaking from the ambient ports?"
Try putting electrical tape over the ambient chamber holes and let the first stage sit pressurized for a few hours. If there is a leak in the ambient chamber, a bubble will form in the tape.
I've found that the most likely cause of erratic IP is a problem with the seat. Perhaps dirt or a scratch or miss matched engraving. The easiest thing to try is a new seat; if that doesn't do it, best to start from the beginning. That included the stem o-ring and while it's removed, run a piece of Scotts Brite in the o-ring groove to make sure there aren't any left over bits of degraded o-ring material left in there. BTW, just because you have a NOS piston, does not necessarily mean the end is not dinged.
If not the seat, then it must be the piston. A small defect in the sealing edge might cause that problem. It should be visible with enough magnification.