Ion regulator adjustment cracked - fix?

[lhamilton1807]

I’ve got an Ion reg that is leaking from the adjuster nut because I tightened the macro line too much. I was thinking of buying a used one, but then I thought there might be a way to fix this.

Has anyone attempted to fix this issue? I figured I could cut off the lug flush with the lower half of the adjuster body, drill out the hole and then tap it with 1/4” NPT threads. Then I’d use a stainless 1/4” male NPT to 1/8” NPT female reducer. To test I’d seal it with Teflon, but then I’d use red loctite to seal it more permanently in place. I’d have a standard fitting and a hex lug to adjust the pressure, just like stock.

Thoughts? Figured if I screw up the adjuster, I’ll still have a broken adjuster 🤪

[Trbo323]

Seems like a lot of work for a crappy regulator

But, I don't particularly see any issue with your method of fixing.

I would not red lock tight in the macro fitting though, in my opinion the fitting is more valuable than the regulator so I would want to get it out eventually

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[Trbo323]

Wait! One thing I just remembered, not sure if it will effect anything you want to do but those adjustors are reverse threads on the ion regs.

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[Alexndl]

Its probably cheaper to buy a used one for cheap and keep this one for parts...

how much is the reducer?

[lhamilton1807]

Fitting is $4 shipped from the bay.

https://www.ebay.com/itm/385207710633?var=653084877640

It’ll take a while to arrive but this project isn’t at the top of my list so that doesn’t bother me. A $4 fix for a crappy reg that’s already broken seemed pretty low risk. Just wanted input to see if I’m missing something obvious.

I’m aware of the reverse threading of the internals - I cracked the adjuster after I took it all apart and rebuilt the reg 😖. I was only going to loctite the reducer fitting into the housing so that when adjusting the pressure it wouldn’t back out. The macro line fitting would be sealed with either blue loctite or Teflon tape.

[Jordan]

You don't need the adapter, just cut the hex portion off and drill deeper/tap for 1/8"-npt. I had one fixed that way, worked great. Just use the hex on the macro fitting to adjust.

Bacci sells cheap used macro fittings if you're reluctant to use up a new one.

I don't understand the hate for Ion regs, they're fine for what they are.

[lhamilton1807]

I’ve read Ion regs can be lemons but that they can also work just fine. Figured I’d rather not throw it away at any rate. Interesting idea to just use the fitting instead. I’ll give that some thought!

[Trbo323]

I don't understand the hate for Ion regs, they're fine for what they are.

They work as regulators, that's about the only up side.

They are ugly with or without the cover, reverse threads were a terrible idea and make it so these get jacked up by people who are taking them apart for the first time. If you have a socket with any kind of lip the brass nut that holds everything in is really easy to strip. I had to modify one of my sockets just for ion regulators and I'm sorry but paintball, at this point (and when the ion was made) should be way WAY past the point of needing a specific tool for any individual marker let alone one just to fix a design problem that was not caught

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[Jordan]

They work as regulators, that's about the only up side.

They are ugly with or without the cover, reverse threads were a terrible idea and make it so these get jacked up by people who are taking them apart for the first time. If you have a socket with any kind of lip the brass nut that holds everything in is really easy to strip. I had to modify one of my sockets just for ion regulators and I'm sorry but paintball, at this point (and when the ion was made) should be way WAY past the point of needing a specific tool for any individual marker let alone one just to fix a design problem that was not caught

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What did you need to modify on the socket?

[Trbo323]

What did you need to modify on the socket?

That little chamfered edge they usually have was too much. The brass piece in the regulator doesn't have a tall enough lip so the socket jumps off the nut and strips it in the process

For some reason my photo won't upload right now

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[lhamilton1807]

They work as regulators, that's about the only up side.

They are ugly with or without the cover, reverse threads were a terrible idea and make it so these get jacked up by people who are taking them apart for the first time. If you have a socket with any kind of lip the brass nut that holds everything in is really easy to strip. I had to modify one of my sockets just for ion regulators and I'm sorry but paintball, at this point (and when the ion was made) should be way WAY past the point of needing a specific tool for any individual marker let alone one just to fix a design problem that was not caught

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I sense a bit of anti-Ion reg hostility. Let’s all calm down and sing kumbayah for a moment, k? 😜

To your point, all the WTH!?!?! design choices you mentioned are valid points. I’m one who actually reads the manual (or more often watches a YouTube video) before jumping into a new-to-me project, paintball or otherwise. Disassembly was a breeze and my deep socket worked fine. Over tightening was my fault. If I rescue an ugly reg for use on a plastic-bodied gun, I’ll be happy to go to the field and play paintball with it. My BE Stingray is as ugly as hell and isn’t a high performance machine, but it’s fun to tag people with it nonetheless. I won’t feel ashamed to have an ugly Ion that still effectively plays the game.

[Trbo323]

Nobody said you should be ashamed of it. But be the proud owner all you want, that doesn't make it a good design either. I can love my Ford pinto to the moon and back, that doesn't mean it won't explode into flames when it gets rear ended.

And yes, I do hate it, I think it's one of the more piss poor designs for a regulator out there. They reverse threaded the regulator so a right turn would make the velocity go up, but just like you said, if you read the manual this doesn't matter. Not to mention, they put a gauge on the side of the marker

As much as I do hate it even I'll admit it does work

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[lhamilton1807]

So moving on…
I have some time tomorrow and will try to fix the reg as Jordan suggested. I’ll post the results. Lots going on at home though, so it might be this weekend.

[JeeperCreeper]

Interested in the results myself. I have 2 regs that have the crack

[lhamilton1807]

I JUST got this taken care of. Didn’t have time last weekend and work’s been a bear the last few weeks.

I made soft jaws out of a piece of 2x4 and drilled a 13/16” hole, then zipped it in half with a skil saw. Painter’s tape just for good measure. A hacksaw was used to cut off the cracked collar.

After sanding it down flat, I used a 11/32 drill and a 1/8” 27 NPT tap. My tap needed a lot of extra room at the bottom of the hole, so I had to go pretty deep. I ended up boring past the hole for the small retaining screw that keeps the reg from backing out while under pressure, but in the end just wrapping both that little screw and the swivel fitting in Teflon made for a great seal. The adjuster end was polished with a cloth wheel and jeweler’s rouge. Aired up, sealed just fine.

[Jordan]

Nicely done!

[lhamilton1807]

Thanks a bunch for the idea for just skipping the extra reducer fitting. This worked pretty well. It’s not black but… it’s a cheapo ion that I got in a bundle and now it’s working. I also slapped in a new Clippard qev that I found on the bay - quite the difference from stock! Woot!

[JeeperCreeper]

Awesome thank you

[Brianeric26]

I fixed this issue way easier just filled the crack on the inside with black automotive silicon