Fifty years ago, Crosman revolutionized the airgun industry with the introduction of the Powerlet. Since its introduction, most CO₂ airguns were designed specifically to fit this ingenious power source. And, to this day, they still play a major role in the industry. However, to put the importance of the Crosman 12-gram Powerlet in historical prospective, we’ll need to explain how they came to be.

Go back circa 1890, when CO₂ was made available to the public for the first time in Paris. Paul Giffard, a Frenchman who was in the business of selling pneumatic airguns, introduced the world to CO₂ as a new way to power them. Introduced with great fanfare as an alternative to powder firearms, the Giffard guns could not compete and were not commercially successful.

It wasn’t until forty years later that Crosman general manager and treasurer, Philip Yawman (P.Y.) Hahn decided it was time to reintroduce CO₂-powered airguns to the public. He developed a CO₂-powered pistol and modified the Crosman Repeater (model 102) rifle by connecting it to large CO₂ tanks using a long hose.

To introduce the first Crosman CO₂-powered airguns, Hahn headed to the 1931 NRA National Matches at Camp Perry. These matches were run as an Army marksmanship program, but State champions and even civilians could compete in small bore, rifle and pistol competitions. Vendors were allowed to set up booths or tents along Sutler Row, located directly next to the firing lines. As matches were completed, contestants exited the field via Sutler Row, providing exhibitors the opportunity to demonstrate and sell their products. The Camp Perry demonstration was a hit and throughout the 1930’s and 1940’s, Crosman CO₂ airgun galleries were a popular form of entertainment at many U.S. carnivals and amusement parks.

With the end of World War II, Hahn wanted to expand the use of CO2 and asked his newly hired chief engineer, Rudy Merz, for some ideas. According to Merz, it was the ready availability of war surplus tanks used for inflating life rafts that inspired the development of the revolutionary "CG" (Compressed Gas) gun. The "CG" gun was a standard model Crosman rifle with a detachable four ounce CO₂ tank attached to the bottom of the gun. Still, it freed the CO₂ airgun from being attached to large, cumbersome tanks. Typically, "CG" guns were sold with a complete rifle range. These proved popular and, by 1949, more than 150 Crosman Rifle Ranges flourished across the U.S. , especially in Rochester, Crosman’s hometown. These shooting leagues were formed along the lines of bowling leagues. Following this popularity, Crosman introduced the first CO₂ powered air rifle for match shooting, the American Shooting Association (A.S.A.) model 121 "CG".  Today, collectors highly prize these original Crosman "CG" airgun models.

The popularity of the "CG" Rifle Ranges inspired Hahn to look at how Crosman could bring the benefits of CO₂ airgun shooting to more members of the shooting public. 

Again, in 1950, Merz brought a groundbreaking advancement with the introduction of single-shot pistols, models 111 and 112, and single-shot rifles, models 113 and 114. These new models utilized a 10-ounce refillable tank that could either be replenished or exchanged for a full tank at a nearby retailer. These first, generally available CO₂ airguns were eagerly received by the public.  However, the bulk-fill CO₂ system was only a stopgap measure until something better could be developed.

That "something better" arrived in 1954. Crosman began a revolution in CO₂-powered guns with the introduction of the models 150 and 157 single-shot pistols.

This Merz design was the first airgun powered by a pre-filled, one-time-use 12-gram CO₂ cylinder – the Powerlet™. Common eight gram CO₂ cylinders, which had already existed for years to charge soda bottles, provided too few shots to be practical for airgun use.  In the beginning, Powerlets were manufactured by Walter Kiddie Company, who made Crosman their exclusive distributor.

In 1955, Rudy Merz designed the legendary model 160 single-shot air rifle. The model 160 was the first airgun to utilize an improved dual-Powerlet design and was intended, in response to requests from the N.R.A., for training purposes. The model 160 remained at the top of the Crosman product line throughout the 1950s and ‘60s and is considered today by collectors and shooters alike as one of the most innovative Crosman designs.

By offering the 12-gram capacity cylinder and specially designed guns to use this improved power source, Hahn believed that Crosman would finally offer customers, young and old, a truly convenient, sensible way to power their guns.

With the great success of the Powerlet, the cost of shipping millions of CO₂ cylinders from Walter Kiddie Company was becoming too expensive for Hahn. Merz was asked to design a way to produce the 12-gram cylinders at Crosman headquarters. Beginning in 1961, all 12-gram CO₂ Powerlets were manufactured at Crosman, using a new, patented 27-step process. Starting with an enormous roll of steel weighing 1,300 pounds, 14 separate machines were required to bend, shape and fill each Powerlet. Initially, the machines were all hand-loaded and Powerlets were walked from machine to machine in bins.  This labor-intensive method yielded only 6,000 Powerlets a day. The 27-step process is still in place, but the machines have been modified, automated and linked together with conveyors for more efficient production.

Today, Crosman is the largest producer of 12-gram Powerlets, manufacturing more than 120,000 each day for airguns and paintball markers. With the Powerlet, not only is CO₂ convenient to transport, it’s also relatively inexpensive, non-corrosive, nontoxic and can be used at any altitude. It’s perfect for just about anyone to use.

The 12-gram Powerlet is still the most practical method of fulfilling Hahn’s dream of utilizing CO₂ to power airguns. The Powerlet has not only affected the way Crosman builds its product line, but it has influenced the entire industry to create innovative airguns that use this power source.

Special thanks to Jock Elliott, D.T. Fletcher, Jim House, Ed Schultz and Doug Wicklund for their assistance in writing this article.