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USD Calypso J Rebuild

Discussion in 'Vintage Diving & Equipment' started by Art Challacombe, Jun 29, 2021.

  1. Art Challacombe

    Art Challacombe Registered

    # of Dives: I just don't log dives
    Location: Hawaii
    15
    15
    Recently, I obtained a non working Calypso J first stage from the mid 1960s. In my first attempt to repair it, I cleaned all metal parts in vinegar water and changed out all o-rings. I also removed and flipped the teflon seat. I cleaned and replaced all rubber parts on the J portion, but kept the poppet seat as I can’t find a replacement.

    Testing went well. IP locked up at 135psi with 2250 in the 72 tank and the reserve actually works at 300psi in the tank.

    So, I connect it to a 1085 second stage and I’m ready to take it on a test dive. I put on a spg to the regulator as I don’t feel comfortable relying on a 55 year old reserve seat even though it works on the surface. I turned on the tank and checked the spg. To my surprise it reads 0 psi. The regulator is breathing fine, but the spg is just slowly inching up the scale. I put a known good spg on, same thing. I turn the tank off and the gauge still has air in hose even after purging the second stage.

    Needless to say, I’m not going to dive with this regulator and used a spare instead. Upon getting it back on the bench, I checked the HP port. As you all know, this port has a teeny tiny hole. I used a jewelers loop and noticed some white looking stuff along the hole. I’m thinking the channel may be blocked and that’s why I’m not getting HP air at the port. It looks like an doubtful fix, so I go for broke and put the disassembled body in boiling vinegar water for 30 minutes. I then blew out the body cavities with compressed air. I reassembled the first stage and tested it with a spg crossing my fingers. Happy, happy, joy, joy, the spg reads at the correct tank pressure. All in all, a great learning experience.
     
  2. GJC

    GJC Solo Diver

    # of Dives: 200 - 499
    Location: Southern California, USA
    675
    579
    Congratulations on a successful restoration!

    Did you happen to notice if there was an HP bushing in it? There was a recall that involved installing the bushing in all the Calypso piston regs built before 1979. Everything after that was built with the bushing installed.

    VDH Blog: Calypso Update.....Danger Will Robinson
     
    couv likes this.
  3. Art Challacombe

    Art Challacombe Registered

    # of Dives: I just don't log dives
    Location: Hawaii
    15
    15
    Hi GjC, thanks for the kind words. No, there was no HP bushing in that era of the Calypso regulator. The first stage on the one I rebuilt is from around 1966 - 1969. After the recall, I believe USD started installing the bushings in the Calypso VI which came out in the late 70’s or early 80’s after the recall. I have a Calypso III that I purchased in 1972 that doesn’t have the bushing and four Caypso IV’s that do have the bushings. Maybe there are some others here that can shed some more information on recall or the history of the early Calypso series.
     
  4. GJC

    GJC Solo Diver

    # of Dives: 200 - 499
    Location: Southern California, USA
    675
    579
    The recall occurred after 1 instance of a regulator failing that shut off all gas supply (notice attached}. Any that were serviced after the recall should have the bushing installed. Use without the bushing at your own risk.

    VHD had bushings but are out of stock right now Store | Vintage Double Hose
     

    Attached Files:

    couv likes this.
  5. Art Challacombe

    Art Challacombe Registered

    # of Dives: I just don't log dives
    Location: Hawaii
    15
    15
    The Calypso regulator I rebuilt is model 1051(1048-00 first stage). The recall notice is for the 1083 and 1084 models. Now, I’ve rebuilt all of them over the years and the functional design as well as the seats are almost identical. I see no reason why the earlier models were excluded from the recall, but my training is from many decades ago. Perhaps someone can shed some light on this.
     
  6. GJC

    GJC Solo Diver

    # of Dives: 200 - 499
    Location: Southern California, USA
    675
    579
  7. Luis H

    Luis H Instructor, Scuba

    # of Dives: I'm a Fish!
    Location: Maine
    3,031
    1,374
    I thought the recall applied to all the Calypso III and the early IV and all the different Calypso J. They may have had a limit on how old of a regulator they consider servicing under the voluntary recall, but that is just a guess.

    I happen to have diagrams and some information that may be handy.

    calypso recall_Page_1.jpg

    Pages from Calypso III  Pages III   from Aqua-Lung Repair Manual-3.jpg


    Pages from Calypso J older  Pages from Aqua-Lung Repair Manual.jpg
    Pages from Calypso J  Pages from Aqua-Lung Repair Manual-2.jpg


    51279348888_b506e44f27_h.jpg



    Calypso IV rev-2_Page_2.jpg
    Calypso IV rev-2_Page_3.jpg

    Calypso IV rev-2_Page_1.jpg


    Calypso bushing mark.JPG
     
    couv and axxel57 like this.
  8. Art Challacombe

    Art Challacombe Registered

    # of Dives: I just don't log dives
    Location: Hawaii
    15
    15
    Happy Independence Day everyone.

    A study of the parts of the Calypso J’s from the sixties to the seventies and early eighties shows some important differences such as the pistons, springs and caps. Even the seats have subtle differences. I have tried interchanging the parts and only the seats worked out for all models. As an example, here is a photo of the springs and caps from 1051calypso J and 1071 Calypso III. The 1083 and 1084’s from the eighties have additional changes.
     

    Attached Files:

    axxel57 and couv like this.

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