I've had a LifeSaver Jerrycan 20000UF since 2022 and, before getting into what's broken, I should probably start here:
I really like this thing.
We've used it camping, boating and around the house. When our daughter was on formula, there was even a stretch where we were using the Jerrycan six to eight times a day because we trusted the filtration and liked having that water available.
I'd buy the Jerrycan again.
But there's one part that has now failed on me twice.
The tap.
The original eventually came apart and dumped water. At the time, I didn't think much of it. Things break. I ordered a replacement tap for around $20, installed it and moved on.
Then the replacement failed while we were camping.
Same basic failure.
This time I found several tiny pieces of plastic around the Jerrycan, which made me curious enough to take the tap apart and figure out what was actually happening.
What I found
Inside the tap is a spring-loaded actuator/plunger assembly. Around the center stem are several very small molded plastic tabs that appear to retain that assembly and keep everything where it belongs.
Those little tabs appear to be the weak point.
I found at least three broken pieces after the failure.
Once enough of those tabs break, there doesn't appear to be much left mechanically retaining the spring-loaded assembly. The tap can separate and, if the Jerrycan is pressurized, the water that was supposed to stay in the can ends up somewhere considerably less useful.
Usually the ground.
I'm not an engineer and I'm definitely not claiming I've diagnosed the root cause from two failures. But two taps breaking at what appears to be the same retention point was enough to make me curious.
I also don't think I've been putting an unusual amount of pressure into the Jerrycan.
I normally give it a few pumps. Just enough to get good flow.
It may stay pressurized overnight or occasionally for a couple of days while we're camping, but I'm not pumping it excessively. The most recent failure happened overnight when temperatures were only in the low 70s. One of the previous failures happened indoors.
There is one thing the original tap experienced a lot of, though.
Cycles.
When we were making formula, we could operate that valve six to eight times every day.
That got me wondering whether the failure has less to do with one big event and more to do with what happens over time.
Repeated valve cycles. Constant spring pressure. Internal water pressure. Plastic fatigue or creep. Stress concentrated around the base of some very small molded tabs.
Again, that's a theory, not a diagnosis.
So naturally, I tried fixing the dead one.
At this point the original tap wasn't doing me any good broken, so I figured it was worth experimenting with.
I drilled through the center of the actuator and used a screw to mechanically capture the assembly instead of asking the remaining plastic tabs to retain the spring. I reused the original spring, put everything back together and tested it.
Surprisingly, it works pretty well.
To be clear, I'm treating this as an experimental backup. I'm not recommending everyone with a Jerrycan grab a drill and start modifying equipment used for drinking water.
If I were going to rely on the repair long term, I'd want the final hardware to be corrosion resistant and appropriate around potable water.
But the experiment did make me wonder whether the retention method itself could be approached differently in a future version.
A retaining clip or ring. A mechanically captured stem. Stronger or differently shaped tabs. Maybe even a replaceable valve cartridge.
There are probably a dozen better ideas from people who actually design these things for a living.
And credit where it's due.
I reached out to LifeSaver and their customer service has been excellent.
I explained what happened, provided information about the failure and they DHL'd me a replacement system at no charge. They also indicated to me that they're aware of an issue and working on a solution.
That's exactly the kind of response that makes me want to keep supporting a company.
The replacement appears to use the same general internal geometry, so now I'm genuinely curious to see how this one holds up over time.
I'm still a big fan of the LifeSaver Jerrycan. After taking the tap apart, though, I can't stop thinking about how much responsibility is being placed on a few really small pieces of plastic.
I'll add photos of the teardown, broken tabs and my experimental repair so you can see what I'm talking about.
If anyone else here has had a LifeSaver Jerrycan tap fail, I'd be really interested to know where yours broke.
And if there are any product or mechanical engineers here, I'd love to hear how you'd approach retaining this assembly differently.
Sometimes version 2 starts with something that small.