OK So I have a NeoAir from a real early batch. I have used it with no issues until my last trip. Noticed the pad a little soft the first morning. Actually had to reinflate during the night the second night. Dang, a leak. Gonna happen right?
So I am checking it out in the tub. Find some tiny, tiny leaks. No sign of abrasion or puncture. I used a magnifying glass, nothing. And it is not a stream of bubbles coming through the fabric either. Even with a fair amount of pressure in the pad while submerged a bubble would form slowly on the surface one at a time. So far I have found six spots like this. All on the underside in my general torso area. While I do not use a ccf pad underneath I do preen my site well and always use a groundsheet.
It looks to me like the fabric itself is not airtight. Maybe a coating breaking down? I hate the thought of sending it in to TR to have them replace it with an Xlite.

Good thing Sharpies write underwater.

Something very similar happened with my NeoAir. They sent me a new one no hesitation. But it sounds like you don't want a new one. Not sure there's a solution other than replacement though.

This is a well know problem with the first generation neo airs. Several retailers sent back their first shipments because a significant number of the pads displayed this behavior immediately. My memory was that there was a flaw in the manufacturing process. I would contact therm-a-rest. My guess is they will do a free swap.

--Mark

Bummer. I am awaiting a reply from TR. We'll see.

I sent mine in with a repair RMA I got on their website with a description of the problem (the same as yours) to get it fixed, they sent me back a new Xlite later the same week.

Karl

Yes I am not worried about customer service at TR. I just don't want a Xlite tapered pad that has shown problems here too as a replacement. I want that big rectangle.

Ken, my original leaked from the get go. I did the same, checked for those hard to find bubbles in my bath tub. The replacement has been fine.
Duane

Perhaps you could get the new XLite and post a message on the gear swap forum to trade the xlite for an original neo-air?

For what it is worth, I have a regular xlite that I just recently purchased and have used on two trips so far with out any issues.

What size are you getting Ken?

I have a Large and Regular NeoAir (original) that I could trade if you need/want. My regular is pretty new as I had the same thing happen to mine and they replaced it. The Large was already 2nd (3rd?) generation.

I am using the XLite right now myself. I just got back from a trip that saw the temps surprise me big time, dropping to 36 F. (It was supposed to be 45 for a low.) I froze from my tiny 9.75 oz 45/50 F quilt, but the pad was not cold.

Ray

Edited by rayestrella on 06/01/2012 07:48:41 MDT.

I have a large. I have a large All Season also. I don't really like the tapered design of the Xlite. Bad decision I think not to offer a rectangular large pad. And have any of you seen the thread about the Xlite insulation delaminating? So maybe it is time to look at Exped.

@Ray. Thanks for the awesome offer. Mine goes to TR tomorrow. Will let you know.

Edited by kthompson on 05/31/2012 22:46:36 MDT.

I got my shipping confirmation this morning. We'll see what's in the box come Friday afternoon.

Hey Ken,

I got an XLite Large the day they were released and it too had micro holes in it and it deflated overnight without me even laying on it.

TaR inflates all of them in their warehouse for at least 24 hours before they package them up but sometimes I think that is just not enough. It is almost as if they need to apply some pressure on each pad while it is sitting there.

I inflated mine and set it upright in my room and the next morning it was flat.

I did not by mine direct, but I contacted TaR and they had it replaced.

The second one held up very well and used it a few times.


I do disagree with you on the tapered design, I sort of like it, at least at the foot end. It would be somewhat neat if they left the head in squared (where I tend to need more room as a side sleeper) than start to taper it off right around the 50" mark (just past the hips). But still, the full tapered effect is not bad.

That AllSeason is still the best pad out there, by the numbers though.

As for me, I really want one of those TaR Women's 40th Anniversary Edition Prolite sleeping pads. While not a wide and long like you and I like, for a medium size sleeping pad, wow what amazing r-value for weight and cost.

How exactly do I find out if I have the early version or not? I might be having this same problem. My mat seems to lose pressure through the night, but it has yet to deflate enough to wake up on the ground. Anyone know how to tell what generation Neoair I have?

You should be able to get a production date from the serial number on the pad. Contact TR.

Mine had a few 00's in the beginning numbers.

Edited by kthompson on 06/14/2012 21:36:10 MDT.

I finally got tired of my Neoair deflating a little through the night (on every trip since I got it 2 years ago) so I checked it for obvious leaks (none) and then sent it in for warranty work over a week ago. Just got notification on Friday that my warranty claim has shipped back to me from CD. Unfortunately, mine has to travel to Ohio so I won't see what the verdict was or what is in the package I am receiving until next Thursday at the earliest.

Ken -- curious what you got back if you received it already??

Edited by tinkrtoy on 06/16/2012 06:23:44 MDT.

So Mark I sent in my Large NeoAir and was sent a large Xlite as a replacement. Got it on Friday. I am trading that replacement with Ray for another large NeoAir. I do not like the tapered design. No place for my feet. It is slightly smaller all around than the Neo.

Thanks for the update - guess I might get to check out the xlite next Thursday and possibly make that decision too.