Help Choosing the Right Air Cap Size

Be sure to order the correct air cap sets for your specific Fuji Spray gun. Note that the fluid jet and needle MUST always match exactly. However, the spraycap/air nozzle may be one size up or down from the norm. The sizes No. 2 and 3 setups are both ideal for all fine finishing.

Generally speaking, the quality of atomization and finish suffers as you go to the largest size setups (numbers 5, 6, and 7).

Please note that the chart offers you a starting point only as to the setup size to be used. The best way to decide is by experimentation. If you are using the #2 setup and wish to spray faster, wetter, then switch to #3.

IF YOU DO NOT PLAN TO SPRAY WALLS AND CEILINGS, THEN THE ONLY TWO SETUPS YOU WOULD EVER NEED ARE THE #2 AND THE #3.

The air cap set sizes:

#1....0.8mm (.031”) — Super-fine output — nano products, inks, shading, airbrush work, anything that requires an extra fine spray. For artists, small surfaces, touch up, shading, stains, thinner, zinc. SUNLESS or Xpc spray gun only.

#2...1.0mm (.039”) — Fine output — Most “fine finishing” — water-based lacquers, nitrocellulose lacquers, sealers, cellulose, acrylics, synthetics, polyurethane stains, varnish, glitter paints, primers.

#3...1.3mm (0.51”) — Medium output — Similar to #2 but more coverage. Especially suitable for automotive enamels, nitrocellulose lacquer, catalyzed lacquers and latex where finer finish is required such as louver doors, trim, cabinets (see article on latex). Also good for varnishes and oil-based paints.

#4…1.5mm (0.59”) — Medium output — Similar to #3 but with more coverage (useful for walls, ceilings, autos) — Especially suitable for automotive enamels, nitrocellulose lacquer, catalyzed lacquers and latex where finer finish is required such as on louver doors, trim, cabinets. Also good for varnishes, primers, and oil-based paints. (Higher output allows you to spray fast drying finishes to obtain better leveling.)

#5...1.8mm (.070”) — High output — for larger surfaces, thick layers, spotted effects — for sealers, varnish, polyurethane, oil-based paints, enamels, epoxy, plastic, adhesives, floor paving paints, latex (on walls), splatter paints, multi-fleck, etc.

#6...2.0mm (.078”) — Extra high output — very heavy flows, fast coverage — for stone finish paints, texture coatings, industrial primers, multi-fleck paints, latex on walls and ceilings, etc.

#7…2.5mm (0.98”) — Very high output — extra heavy flows, fastest coverage — for stone finish paints, texture coatings, industrial primers, multi-fleck paints, latex on walls and ceilings, etc. (We used a #7 air cap on a Fuji T70 spray gun in two videos of spraying a house)

Printable one-page air cap setup size selection guide from Fuji Spray (Opens in a new tab.)

If you’re buying a Fuji Spray system, consider choosing a package that includes the specific extra air cap(s) you need. This gives you a discount and saves the shipping cost of ordering them later.

This video shows changing an air cap on an older spray gun, but the same process applies to newer Fuji spray guns. See your spray gun manual for any details.

Changing air cap setup on a Fuji Spray T75G HVLP Spray Gun

Fuji Spray also has an excellent article on air cap setups explaining them in detail.

Air Cap Setups for Fuji T-Series Spray Guns — T70 and T75G

Click on an image below for details and to place an order.

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Help Choosing the Right Air Cap Size

The air cap set sizes:

Air Cap Setups for Fuji T-Series Spray Guns — T70 and T75G

Air Cap Setups for Fuji Gxpc Spray Gun

Air Cap Setups for Fuji M-Model Spray Guns (for Semi-PRO 2 and Hobby-PRO 2)

Air Cap Setups for Older Fuji Spray Guns

Air Caps for Fuji Compressor Spray Guns