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Huma rebuild help

If it's passing the full reservoir pressure, either the seat (plastic disc) is damaged, or the O-ring on the brass adjuster is failing. From your description, it's most likely the latter. My guess is the O-ring is extruding into the gap when it is dealing with the elevated stress of a full reservoir. It's a M1.5 x 5.5 Buna-N 70 durometer.
 
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Thanks for the advice. It gave me a chance for a fresh look. It turns out I wasn't smart enough to make a technical mistake. My rebuild was perfect. I was so zoned into the reg I forgot about the Oring on the base of the plenum. Without It will work when you first fill it but not when you drain it and refill. Thanks again Maybe next time start with Did you forget an Oring stupid?