Craftsman air compressor gaskets (E100959) in TPU

Replace the 3 blue gaskets in Sears/Craftsman/Powermate/Husky air compressors (equivalent to gasket kit E100959)
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updated March 12, 2024

Description

PDF

Why:

I picked up a Craftsman air compressor model 921.152101 for free - it ran but wouldn't build pressure past 40psi. Upon disassembly, I discovered blown pump gaskets. Why buy when you can make? So, I whipped these up in CAD (15 minutes), printed them in TPU (1 hour), and re-assembled in 15 minutes. In less than 2 hours, I had a fully working air compressor!

What:

These replace the three blue gaskets that come in replacement kit E100959 used in many Craftsman/Powermate/Husky branded 1-2HP electric/oiled air compressors manufactured in China. Typically, the black and metal gaskets are OK and it's just the blue ones that fail. If there is interest, I'll model the black one and add that here.

3D Print notes:

  • TPU or TPE filament with (40A - 70A durometer)
  • 100% infill
  • 4 perimeters
  • top layer ironing optional
  • 0.2mm layer height

Gasket thickness is 1mm but you can scale 150% to 1.5mm to get additional squish for harder durometer (>70A) filament.

Install notes:

You must carefully scrape away all remnants of the old blue gaskets with a razor blade and clean up any bits with a soft wire brush or hard plastic brush and alcohol. Ensure no blue bits drop down into the pump cylinder. Follow one of the many guides on Youtube for specific steps. After assembly, run the pump a few times to heat and soften the gaskets, then tighten the head gasket bolts an additional ¼ turn.

Note that the TPU will NOT last and the upper gasket will blow out eventually. When it does, just order the real kit.

 

Design notes:

  • upper circular gaskets:
    • inner diameter: 51mm
    • outer diameter: 80mm
    • separator bar: 5mm
    • bolt pattern: 4x65mm PCD
    • bolt hole diameter: 6.75mm
  • lower square gasket:
    • 64mm x 64mm
    • 5mm radius fillet
    • bolt pattern: 4x65mm PCD
    • bolt hole diameter: 6.75mm
    •  

Works with many 1HP oil-lubricated made-in-China compressors from 2-10 gallons including:

  • Craftsman:
    • 921.153100
    • 921.153101
    • 921.153120
    • 921.153620
    • 921.153640
    • 921.164780
    • 921.166360
    • 921.166370
    • 921.166380
    • 921.166390
    • 921.166400
    • 921.169230
  • Powermate:
    • VSF1080421
    • VKF1080418
    • VPP1080318/VPF1080318
  • Husky:
    • L13HPD

Tags



Model origin

The author marked this model as their own original creation.

License