Graco Fusion AP vs PMC AP-2: Air-Purge Spray Gun Comparison Review

Walk into almost any spray foam or polyurea shop and you will find a Graco Fusion AP or a PMC AP-2 on the hose. Both are air-purge impingement guns, both handle foam and coatings, and both have loyal fans. Here is our ArmorThane Tech Team comparison, using the manufacturers' published specs.

The quick verdict

• Choose the Fusion AP if you run Graco equipment, want tool-free chamber changes, or want the widest parts support in our shop.
• Choose the AP-2 if you run PMC proportioners, like the separate chamber and Pattern Control Tip design, or already stock AP-2 parts.

Neither gun is a bad choice. The real decision is usually about parts, pattern control and what your crew already knows.

Side-by-side specs

Sources: Graco product page 246102 and Fusion AP manual 309550; PMC AP-2 product page and AP-2 service manual.

Mix chambers and spray patterns

Fusion AP

Graco's round chambers use part numbers that describe the port size. An AR5252 has 0.052 in ports and is the 02 size; an AR4242 is the 01. Graco's manual lists round chambers from AR2020 (000) through AR8686 (05), and flat chambers (AF series) paired with flat tips for wider fan patterns. The quick-release fluid housing lets you swap chambers without tools.

PMC AP-2

The AP-2 separates mixing from pattern. Chemical impinges in the mixing chamber, then travels down the chamber and out the PCT. PMC publishes flow for each chamber: for example, an 02 chamber (0.052 in) is rated about 12 lb/min at 1,000 psi and 22 lb/min at 2,000 psi, while an 04 (0.069 in) is rated 25 and 47 lb/min. The X half sizes (00X, 01X, 02X) let you fine-tune output between standard sizes.

Daily maintenance compared

Both guns reward the same habits:

1. Grease at shutdown. Graco says to grease the Fusion AP until a grease mist sprays from the nozzle, two shots maximum. PMC says to grease the AP-2 mixing chamber until a fine mist of grease sprays from the gun.
2. Close the manual valves and relieve pressure before any work on the front end.
3. Check filter screens in the check valves or screen screws. A plugged screen is a common cause of an off-ratio pattern.
4. Inspect side seals for scoring or buildup, and replace O-rings as a full kit rather than one at a time. PMC's manual specifically says to replace all O-rings in the kit.

The Fusion AP's tool-free front cap and fluid housing make chamber changes quick. The AP-2 has more individual front-end parts, but a worn PCT can be replaced without replacing the chamber.

Parts availability

This is where the shop you buy from matters. For the Fusion AP we stock a deep bench: the stainless side seal kit (246348), A and B side seal cartridge kits (246349, 246350), the complete O-ring repair kit (246355), A and B check valve assemblies (246731, 246352), the front end replacement kit (246361), springs, triggers, air caps and more. For the AP-2 we currently list the A and R side screen screw assemblies (202409, 202410) and the 2.5 gallon solvent flush pot kit (200426), plus complete AP-2 gun packages. As our manufacturer agreements grow, so does the catalog; if you need an AP-2 part you do not see, ask our team.

Browse everything in Parts & Rebuild Kits, or use the Gun Parts Finder to tap parts on exploded diagrams of Fusion guns and the PMC Xtreme.

Which applicator each fits

• Fusion AP: Graco Reactor owners, crews that change chambers often during the day, and applicators who want next-day parts coverage from one source.
• PMC AP-2: PMC proportioner owners, applicators who like tuning pattern with the PCT, and shops that already carry AP-2 spares.

If a gun starts spraying off-ratio, spitting or leaking, run it through our Troubleshooter before you tear it down. It will point you to the likely cause and the exact parts to fix it.