Has anyone had a pancake compressor fail?

[u/02C_here]

The manual says drain the body occasionally and that rust inside the thing is the enemy. On humid days I get water out of the drain. At some point, it's going to fail, I reckon. Has anyone had one fail? How old was it? And how catastrophic - was it just an extra noisy pop or did it go like a shrapnel grenade?

[u/Ok-Drama-3769]

The red porter cables are indestructible but loud.

[u/Morganvegas → u/Ok-Drama-3769]

The guys I work with are horrible to tools. It’s why I use my own instead of what’s supplied by my employer.

They have yet to destroy a porter cable compressor and they literally just wing them into the back of the van. Roll around in the bed, smashing into everything.

Simple machine, does exactly what you need it to do.

[u/redpukee → u/Ok-Drama-3769]

Yup, 30 years on mine. Light use. Had to replace the drain valve.

[u/New-Examination4783 → u/Ok-Drama-3769]

Mine caught on fire while nailing up strapping after a good 10 years or so of use.

[u/Ok-Drama-3769 → u/New-Examination4783]

RIP

[u/joeycuda → u/Ok-Drama-3769]

I had one for prob 15yrs, it developed a leak, and I just ended up tossing it. I'm sure I could have fixed it, but I just hated how deafening it was and wanted an upgrade. I went to HF when they were on sale (knowing you get what you pay for), intending to buy something small and portable, and bought a 30ish gal vertical, that's portable, but kind of a PITA bulky/heavy. After a year or so, it quit working. Currently replacing the switch ($15 on Amazon). It got to where it wouldn't kick on if tank already pressured up, but would operate fine if tank empty. Pretty sure it's the pressure switch.

[u/ClosedL00p → u/joeycuda]

That doesn’t sound so much like a pressure switch failure. Typical failure modes there are they won’t shut down when they reach max pressure and just keep running until they hit the pop off valve, or they just won’t power on at all.

If it pumps up fine from empty, but then won’t cycle after it bleeds down ~30psi , there’s a good chance it’s fighting head pressure either from the unloader valve being stuck or the check valve back feeding to the pump

Also depends on what type of pressure switch it is as well. If the pressure switch and the on/off switch are two separate parts on your unit……the stuff I wrote applies. If the on/off switch is part of the pressure switch, then the unloader valve is actually part of that switch

[u/joeycuda → u/ClosedL00p]

I think in my case, the unloader valve is part of the switch. I bought a 'cheap Chinese replacement' that functionally, probably is no worse than what came on it. It's just that one of the doodads on it comes out at a right angle on the oem and straight down on the replacement, so I need to get a 45 deg fitting to attach that hard line. Thanks for all the info though, I appreciate it.

[u/ClosedL00p → u/joeycuda]

If it’s that style switch then replacing it certainly could solve your problem. Easy way to check is to let it pump up to cutoff pressure and then crack the fitting loose on the discharge from the pump to the tank and listen for any air coming leaking from the tank. Should hear a momentary “tss” at most and then nothing else.

Do you run the compressor off of an extension cord? Or plugged directly into a 20a outlet? Can’t tell you how many times I have to go over this subject with customers bringing compressors into my shop for repairs……then find out they’ve trying to run compressors drawing 15+ amps of a 50ft dollar general Christmas light extension cord

[u/nail_jockey → u/Ok-Drama-3769]

I had one for probably 4 years before it finally died. Admittedly we did plenty of framing with it when we didn't have a bigger compressor handy.

[u/fishin_pups → u/Ok-Drama-3769]

I still use mine I bought in 1999

[u/Super-G_ → u/Ok-Drama-3769]

I was so happy when mine finally died and I was able to replace it with the little 2gallon Makita Quiet Series compressor. Being able to talk over it while it's cycling is sooooo nice.

[u/Ok-Drama-3769 → u/Super-G_]

Almost need ear plugs when using it 😂

[u/Super-G_ → u/Ok-Drama-3769]

Not almost.

[u/human743 → u/Ok-Drama-3769]

So they use un-rustable steel for the tanks unlike other brands?

[u/cb148 → u/Ok-Drama-3769]

Even if it does break, you just replace it at Home Depot on a black Friday sale for $100. Can’t beat them.

[u/cleetusneck → u/Ok-Drama-3769]

So mine literally sat outside for about 12 years because I use it to pump up all the tires on everything. Gauges were so smooshed off of it. You couldn’t read them. Eventually, the rubber hose had a tiny leak. That sucker was tough.

[u/PiscesLeo → u/Ok-Drama-3769]

One of my loudest tools, I’ve had it 20 years or so. Can’t wait til it dies to get a quieter one

[u/johnjackcomicartist]

I drain my red porter cable like twice a year and it still works after 12 years of regular use

[u/Hot-Friendship-7460]

The motor will die before the tank goes.

[u/Cosmo_MV]

Used them for years. Bostich was my last one. Died because we had to leave a job for a while , covered w a barrel and it rusted a bit. When turn on the belt snapped.
We drain all compressors daily. It’s a rule in my job sites so we don’t squirt water + oil from guns on the product.

[u/curious1playing]

"Drain occasionally "? I Drain after every use...all that water is getting pushed down the hose into the tools...

[u/Master_Brilliant_220 → u/curious1playing]

This is why we oil the air guns daily(usually three times a year.)

[u/earfeater13]

I still use a porter cable from 15 years ago. You'll be fine.

[u/dirtkeeper]

Similar experiences, rarely even drain mine. I think you would get a pin hole leak first. For it to explode it’s seems there would have to be a very equal deterioration that. The tank gets right on the edge of failure along the whole seem . Doesn’t seem likely .

[u/Monkeefeetz]

I had a double hotdog style tank get a pinhole from rust because I didn't drain it. It didn't explode it just suddenly started leaking. I was there at the time so I shut it off 

[u/padizzledonk]

30y and ive never even heard of on fauling- dead motor, fucked up compressor rod, sure, never heard of the tank failing

And fucking basically 0 people ive ever met drain them daily or even weekly lol.....usually they sit until you can feel and hear the water sloshing around in there before anyone remembers youre supposed to drain the fuckin things

[u/ACatsWrath → u/padizzledonk]

I drain mine after every project. Not sure how I got into the habit but if I use it for a day or a week and I know I won't be using it again for a week or so, I drain.

[u/padizzledonk → u/ACatsWrath]

Youre a better man than most lol

I try and drain them periodically but im not even going ro pretend like its after every project lol-- definitely before i know its going to be stored for a while

[u/hudsoncress]

Unfortunately pancake compressors never die, they continue to suck and stand in the way of a replacement for the rest of your life. Mine has sat with moisture in the bottom for literally years at a time and that bastard will not die.

[u/Super-G_ → u/hudsoncress]

Just throw it out! Get a quiet one and live a more pleasant life. Mine finally died and I got a 2gal Makita to replace it. Wish I had done it on day one instead of ever having to listen to that god awful racket.

[u/hudsoncress → u/Super-G_]

I have a really nice Senko micro compressor that is great for trim. I keep the pancake around just for framing. Due for a new framing nailer setup next big project. Not sure if I'll go cordless or not.

[u/Super-G_ → u/hudsoncress]

I'm surprised that you can do much framing with a pancake. I found the draw and constant cycling to be a bit much so I got a bigger oiled compressor for framing, siding, and roofing. I am now happily 100% pancake free!

[u/MX_sixto_TX]

No but you should still drain after done using. Especially after using in humid days. Industry trends show stuff is being made cheaply and with lesser quality now a days. You probably won't have a rusty hole developing anytime soon but rust could make removing the valve difficult in the future if need be.

TBH the only damage that has occurred on my personal compressor has been fittings becoming loose from the vibration.

[u/Majestic-Lettuce-198]

i’ve got a bostitch 5 gal that probably 10 years old. It’s spent at least 5 new england winters outside uncovered. It looks like shit but it works. Most of those pancakes are all the same thing and pretty much bulletproof.

[u/earthman34]

I've had a shitty Tool Shop compressor for 25 years. Still works great. I did replace the switch and regulator at one point.

[u/02C_here → u/earthman34]

That's interesting. Cheaper to fix then replace?

[u/earthman34 → u/earthman34]

Yeah, the parts aren't expensive.

[u/whackozacko6]

I drain mine after every use. I have never had a drop of water come out and I've had the thing almost ten years

[u/MT-Estimator]

When they eventually rust out they just start leaking air from a pin hole.

[u/Rootin-Tootin-Newton]

I’ve had mine for over 25 years. At the end of every use, I open the drain plug on the bottom.

[u/Osiristhedog1969]

Back in the 90s I saw a very rusty old Bostitch fail around the seam. Bottom stayed, top shot up 15+ feet in the air spinning all topsy turby with cords still attached. Definitely could have killed if one was leaning over it

[u/02C_here → u/Osiristhedog1969]

That's the first catastrophic response. Seems like one should just scrap it out if there's visible med to heavy rust. And generally stay back a few paces when it hasn't been started in a bit and you'd be OK.

[u/JudgmentGold2618 → u/02C_here]

it is no joke . Lived in Ohio for about 4 years . I heard it about 3 times in the local news compressors blowing up and killing someone.

[u/Osiristhedog1969 → u/02C_here]

Been constantly around them since the early 90s and that's the only catastrophic failure I've witnessed. At a buddy of mines big old ancient wood shop they had one of those very large horizontal tanks from my grandpa's era. They were working in the other room. It broke the Heart Pine Floor, Subfloor, a couple Floor Joist and at least one Ceiling Joist,  heavy duty old timbers. It easily could have killed

[u/02C_here → u/Osiristhedog1969]

Industrial accidents are no joke. Been in manufacturing for 40 years and have had my share of them.

[u/mr_raymond_chen]

I never drain the water, you will be fine

[u/Long_Woodpecker_3615]

For the porter cables, The gasket on the piston will go before the tank fails, but drain it and your tools won’t spit at you. The piston gasket is easy to change and available as a whole assrmbly for $50 on Amazon.

[u/Sgtspector]

I've got a porter cable that's over 20 years old. I drained it about every blue moon. Still no leaks and holds air indefinitely. It recently started making noise and stuttering when its on but still works. I just used it to redo the roof on my shed. No problem running my framing nailer or the roofing nailer.

[u/Square-Tangerine-784]

Have one in the barn that hasn’t been drained in 20 years. Bostich. So annoyingly loud that I can’t have it on jobs so it’s to fill up tires and blow out dust from tools and sanded parts.

[u/Onetrickhobby]

Had the drain fail on one. It was like 10 years old. I drain them every once in a while since I’m by the beach. Just started to whistle out the drain. Replaced that and a while later the valve plate went bad. Fixed it but it never ran properly again. Tossed it when depot had the set on sale with new nail guns.
I have 3 porter cable ones. Pretty bullet proof. Had a few bostic ones that lasted 25+ years. Never had one explode.

[u/Full_stack1]

I had carbon buildup under the flutes in the reed, was causing me to not get above 50 psi, cleaned it out was good

[u/Summer184]

As long as you're taking reasonable care of it, It's probably more likely an electrical issue will finally kill it. I've had a cheaper one for years that stopped working and I traced it back to the power switch, I was able to fix it and it's still running.

[u/BoreBitBob]

I have seen compressors die from rust and neglect but draining the tank regularly makes a big difference.

[u/Crafty_Produce7807]

I had some weird second hand compressor for a bit. When it died on me, I dug around the motor & found it was 23 years old.

[u/ichiban4713]

Twice. I bought a Makita that runs at a low rpm, and it will last forever. Super quiet, too. The pancake compressors are junk, and they’re louder than a freight train.

[u/1320Fastback]

I've had them fail over the years and 9/10 it is the like fabric/leather piston ring or something in the reed valves. I used to try and fix them and had success but now just toss it and buy a new one.

[u/JB2315]

Ive had various brands fail. The piston rings fail, the rod bearings fail, rod bolts break, conn rods have broken. Never have I had a tank fail.

[u/cosmokingsley]

A tank is a tank. 90% of the time its no big deal, and they will "pip". But its impossible to guess the extent of rust in certain parts of the tank. In my experience its usually a needle sized hole.
I have a nice 80gal belaire back in Oregon that belonged to pops. After like 20 years of sitting in a corner unused with like a gallon of water in it, I cleaned it up and put it back in use... like a day later, it had a needle pip in the bottom of the tank. Drilled it, welded it, and its been running regularly for about 5 years, and im not the best at draining my tanks.... its hard to say this would always be the case though.
But on another note. All my other compressors are atleast 20 years old and have zero issues. So im just going to assume, you have a really long time before its even a thing to worry about.

[u/02C_here → u/cosmokingsley]

What kind of weld did you use to fix the leak?

[u/PotentialAd6139]

compressor explosion

[u/02C_here → u/PotentialAd6139]

WOW! That looked like an 8 or 10 gallon job. But the tank failed pretty much as you'd expect. Blow the end off and split the tube.

[u/blbd]

If you drain them right they will go a long time. 

Usually always the pump system dies before the tank. 

Because tanks are required to follow safety laws from ASME in order to legally enter the US stream of commerce. 

[u/fuckalicioussss]

always drain it. too much water will lessen quantity of air and cycle like crazy

always tilt so the petcock is the lowest point and leave open till you use again so condensation doesnt build

tank itself will outlast the components

[u/Woodbutcher1234]

I've an old Emglo double hotdog that I wanted to put back into service but found that the bottom tank now resembles Swiss cheese. Half heartedly looking to find a way to put the compressor on new tanks.

[u/mydogisalab]

Several, I don't buy that style any more.

[u/rwoodman2]

I have a Rolair that is about 33 years old and runs perfectly. More than 20 years of that time it was in full time professional use.

I thought it was expensive when I bought it. In reality it has turned out to be the second cheapest power tool I have ever owned.

I drain it after every time I use it. It has needed a start capacitor and a pressure switch and a couple of tank drain valves in its life. No hint of the tank failing yet.

[u/3boobsarenice]

Yes from old age, they are reeds and a piston no real fix

[u/Turbulent_Head6209]

Drain mine at the end of the day every time I use it. Why wouldn’t you.?

[u/saylynshoes]

I still use my Craftsman I bought in 1968.

[u/YeahPete]

I had an Ingersol Rand 20 gal from probably the 70's just fail on me. It was just a pop noise and a constant air leaking sound. It still worked.

They last much longer than you think. I bought the air compressor 2nd hand in 2012.

[u/OstensibleFirkin]

I had a drain rust out. I stuffed the hole with JB weld. Would I recommend it as safe? No. Does it still run great after 15ish years? Yes.