Traveling with Spare Air

Traveling with Spare Air

Spare Air is the ultimate travel buddy, especially when traveling to exotic destinations using rented or borrowed equipment.

Traveling by Car or Boat

When driving to your dive location, simply keep your Spare Air protected from dust and extreme temperatures like you would a regular SCUBA tank and your dive equipment. The unit can travel fully charged, ready when you need it.

Ground Transportation Best Practices:

  • Store Spare Air in a protective case or bag to prevent damage
  • Keep away from direct sunlight and extreme temperatures
  • Avoid storing in car trunks during hot weather (can exceed 150°F/65°C)
  • Secure the unit to prevent rolling or shifting during transport
  • The unit can remain fully pressurized at 3000 psi during ground travel

Flying with Spare Air

YOU CAN FLY WITH YOUR SPARE AIR!

Flying is only a little more complicated. The war on terrorism has created greater travel restrictions. Please be aware of the following information from the Transportation Security Administration (TSA):

Official TSA Guidelines for Compressed Gas Cylinders:

"Except for personal medical oxygen cylinders, you can only carry an EMPTY compressed gas cylinder onboard a plane. To be permitted (in either carry-on or checked baggage), it must be clearly visible to the TSA officer that the cylinder is empty. Personal oxygen is permitted if the regulatory valve has not been tampered with or removed.

Unless being used for personal medical oxygen, the gas cylinder regulator valve must be completely disconnected from the cylinder (in other words, the cylinder has an open end that allows the TSO to visually inspect the cylinder). TSOs will NOT remove the seal or regulator valve from the cylinder. If the gas cylinder is sealed (the regulator valve is still attached) and not required for personal medical oxygen, the gas cylinder is prohibited, regardless of the reading on the pressure gauge indicator."

Source: TSA.gov, August 2017

Step-by-Step Guide: Preparing Spare Air for Air Travel

As mentioned above, your Spare Air must be depressurized and the regulator removed from the cylinder to allow for visual inspection. Follow these steps when packing for your trip:

Step 1: Depressurize the Cylinder

Empty all the air out of the Spare Air by pressing the purge button until no more air is released. Ensure the cylinder is completely empty—the pressure indicator pin should be fully recessed.

Step 2: Remove the Regulator

Spare Air regulator exhaust disc assembly showing proper component order

Remove the regulator from the cylinder by turning counter-clockwise. The regulator is attached hand-tight and should unscrew easily.

Important: Leave the O-ring, washer, and exhaust discs on the regulator. Do not remove these components.

⚠️ If the regulator does not unscrew easily: DO NOT force it or use tools. Instead, soak the entire Spare Air in a 1:1 vinegar and water solution overnight to loosen any salt corrosion. This is common after saltwater diving.

Step 3: Protect and Pack Your Spare Air

Spare Air Travel Pack with clear carry bag and protective caps

Place the Spare Air in a protective container (plastic bag or box) to keep the unit clean and to secure loose parts.

We recommend our optional Travel Pack accessories:

  • Travel Pack #963 for the 3 cu ft model
  • Travel Pack #966 for the larger 6 cu ft model

Both Travel Packs include:

  • Protective carry bag
  • Dust caps for cylinder and regulator
  • Replacement tank O-rings (025 Combo)
  • Silicone lubricant

Buy Travel Pack #963 (3 cu ft)

Buy Travel Pack #966 (6 cu ft)

Step 4: Pack in Luggage

Pack Spare Air in your checked or carry-on luggage. Both options are permitted by TSA as long as the cylinder is empty and the regulator is removed.

Pro Tips from Experienced Spare Air Travelers

Carry-On Strategy:

"If you place your Spare Air in your carry-on bag, have your Spare Air cylinder and regulator exposed in a separate bin with the cylinder clearly empty with no cover. This way, TSA can quickly visually inspect the empty cylinder. This will prevent delays in the security line.

After you have moved through security, cover the cylinder opening, return it to your carry-on bag, and wait until you arrive at your dive destination or home before reattaching the regulator to the cylinder. Don't forget your Owner's Manual to answer all your refilling and assembly questions."

Travel Pack Benefits:

"The Spare Air Travel Pack is a great accessory providing two caps to protect the threaded end regulator, keep dust out of the cylinder, and comes with a few extra O-rings, too! The regulator cap is great at keeping the diaphragms, washer, and O-ring in place."

Reassembling Spare Air at Your Destination

When you reach your dive destination, follow these steps to reassemble and refill your Spare Air:

Step 1: Inspect Components

Check the tank O-ring, washer, and exhaust discs for any damage or wear. Replace if necessary.

Spare Air 025 Combo replacement parts - exhaust disc, tank washer, and O-ring

Step 2: Lubricate the O-Ring

You may lightly lubricate the tank O-ring with a small amount of silicone spray or grease. NEVER use a hydrocarbon-based oil as it can react with high-pressure oxygen and cause fire or explosion.

Step 3: Reattach the Regulator

Important: Consult your Owner's Manual for the correct installation order of exhaust discs, tank washer, and O-ring on the regulator before attaching the cylinder.

Proper Assembly Order (from regulator to cylinder):

  1. Exhaust discs (check orientation)
  2. Tank washer
  3. O-ring

Thread the regulator onto the cylinder by turning clockwise. DO NOT force the regulator onto the tank. If you feel resistance, stop, unscrew, and start again. Cross-threading can damage the cylinder threads.

Step 4: Refill the Cylinder

Fill your Spare Air to 3000 psi using one of the four refill methods: SCUBA tank, dive shop, compact compressor, or hand pump. View complete refilling instructions →

Step 5: Check for Leaks

After refilling, check the pressure indicator and listen for any air leaks around the regulator connection. If you detect a leak, depressurize, remove the regulator, inspect the O-ring, and reassemble.

O-Ring Replacement Schedule

Replace the tank O-ring after:

  • The product has been disassembled and reassembled 3 times
  • The O-ring shows signs of wear, cracking, or flattening
  • You detect air leakage around the regulator connection
  • The O-ring appears dried out or damaged

Tank O-ring size: 2-016 (available as part of the 027 set or 025 Combo)

A full set of replacement exhaust discs, tank washer, and O-ring are available as the 025 Combo, available online or at any dive shop.

Buy 025 Combo Replacement Parts

International Travel Considerations

While TSA guidelines apply to flights within and departing from the United States, international destinations may have different regulations:

  • Check with your airline: Contact the airline directly about their specific policies for compressed gas cylinders
  • Research destination country regulations: Some countries have additional restrictions on diving equipment
  • Arrive early: Allow extra time for security screening and potential inspections
  • Carry documentation: Bring your Owner's Manual and product specifications in case questions arise
  • Language barriers: Consider printing TSA guidelines in the local language of your destination

Frequently Asked Questions

Can I fly with Spare Air in my carry-on bag?

Yes, as long as the cylinder is completely empty and the regulator is removed so TSA can visually inspect the cylinder. Many travelers prefer carry-on to ensure their Spare Air isn't lost or damaged in checked baggage.

Do I need to declare Spare Air at airport security?

It's not required, but it can speed up the screening process. Place the empty cylinder and regulator in a separate bin for easy visual inspection.

What if TSA doesn't allow my Spare Air through security?

If you've followed the guidelines (empty cylinder, regulator removed), TSA should permit it. If there's confusion, politely ask to speak with a supervisor and reference the official TSA guidelines for compressed gas cylinders.

Can I refill Spare Air at my destination?

Yes! Most dive destinations have dive shops that can fill Spare Air, or you can use your own SCUBA tank with the appropriate refill adapter. Consider bringing a hand pump for remote locations.

How do I prevent the regulator from getting stuck on the cylinder?

Rinse your Spare Air thoroughly with fresh water after every saltwater dive. Salt corrosion is the primary cause of stuck regulators. If diving in saltwater frequently, disassemble and rinse the threads periodically.

Should I bring spare O-rings when traveling?

Absolutely! The Travel Pack includes spare O-rings, or you can purchase the 025 Combo. O-rings are small and lightweight—perfect travel insurance against leaks.

What if I lose a component during travel?

The Travel Pack's protective caps help prevent loss of small parts. If you do lose a component, most dive shops carry standard O-rings and washers. For exhaust discs, contact us or order the 025 Combo online.

Can I ship Spare Air to my destination instead of flying with it?

Shipping regulations for compressed gas cylinders vary by carrier and destination. Most carriers require the cylinder to be empty and properly packaged. Check with your shipping provider for specific requirements.

Suggested Resources

Official TSA Information:

Spare Air Resources:

Travel Checklist

Before You Leave:

  • ☐ Depressurize Spare Air completely
  • ☐ Remove regulator (leave O-ring, washer, discs attached)
  • ☐ Pack in Travel Pack or protective bag
  • ☐ Include Owner's Manual
  • ☐ Pack spare O-rings (025 Combo)
  • ☐ Include refill adapter for your destination
  • ☐ Verify airline and destination country regulations
  • ☐ Arrive at airport early for potential inspections

At Your Destination:

  • ☐ Inspect O-ring, washer, and exhaust discs
  • ☐ Lubricate O-ring with silicone (not oil)
  • ☐ Reassemble regulator to cylinder (check proper order)
  • ☐ Refill to 3000 psi
  • ☐ Check for leaks
  • ☐ Verify pressure indicator shows full
  • ☐ Test purge button function
  • ☐ Mount on BC and practice deployment

Related Resources

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