Introduction: Repair a Broken Ultraflate CO2 Pump

Picture of Repair a Broken Ultraflate CO2 Pump


I broke the cartridge holder of my Ultraflate CO2 bicycle pump by stepping on it.  This instructable shows how to make a new one using standard 3/4 inch PVC pipe and fittings.

Step 1: What You Will Need

Picture of What You Will Need

This replacement cartridge holder is made from 3/4 inch PVC pipe and standard fittings.  You will need a short length of 3/4 inch PVC pipe, a 3/4 inch female threaded coupler, a 3/4 inch round end cap and PVC cement. You will also need a hacksaw or other tool to cut the PVC pipe.  Finally, an electric drill with a 5/16 inch bit can be helpful.

Step 2: Measure and Cut

Picture of Measure and Cut

Line up the end caps so they are the same length as your cartridge holder (In mine, that's 3.5 inches long).
Notice that these PVC fittings have a small ridge inside them, which is a dead-stop for the 3/4 inch PVC pipe to slip to when it's assembled.  While the PVC pipe won't reach the dead stop in a dry-fit, it will get there when you add the solvent cement, which temporarily lubricates it.

Take the dead stop into account to cut a short length of PVC pipe to fit between the two end caps.

Step 3: Assemble the Parts

Picture of Assemble the Parts

Apply PVC solvent cement per instructions. You don't need much.

Push/twist the end caps onto your cut 3/4  inch pipe until it is completely seated, and the assembly is the correct length.

*** Note *** You'll only have a few seconds to do this.  Make it a smooth motion.  Often it is a good idea to mark your PVC pipe to show how far it is expected to go.

Step 4: The Fully-assembled Piece

Picture of The Fully-assembled Piece

Here's a cutaway view.  Let the cement dry and cure for a bit.  Maybe an hour.

Step 5: Special Feature: Drill a Hole

Picture of Special Feature: Drill a Hole


To let you store a CO2 cylinder inside the holder, it's good to drill a hole into the end of the rounded cap.  My BB gun style cartridges have a neck that's about 1/4 inch in diameter, so I drilled a 5/16 hole in the center of the rounded cap.

I may the only person who is clumsy enough to break their Ultraflate bike pump in this way, but now I know how to fix one.

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