It didn't make sense to me that CO2 would be smaller than O2 given that it contains both the O2 molecules plus a carbon. Of course, how atoms actually combine may not be intuitive. So I looked online and it does seem that CO2 is a larger molecule than O2 or N2, not a smaller molecule.

OTOH, it still leaks from the tube faster for other reasons.
Does CO2 leak from tubes more rapidly than air?

Oh, yeah. No comparison.

If I didn't race, I'd probably be happy with any plug system. But if you need to plug a tire fast, nothing beats Dynaplug.

I don't race, but I am a tubeless noob, so easier and faster is worth some money.

How hard would it be to make a plug tool out of brass tubing and a cork that would fit Dynaplug refills?

Anyone have calipers and can measure the shoulder diameter of a plug?

Surely you're not endorsing ripping off the patented design of a proper American company?
If you don't like Dynaplug prices homage designs are available at all the usual sites.

I was assuming the patent was on the plug, nut the plug setting tube.

If you can afford tubeless tyres this is essential. Your first puncture that doesn’t seal will ruin your day otherwise.

If you are making your own DIY tool for personal use then your conscious is clear!

I agree. While ordinary bacon strips are perfectly acceptable, Dynaplug is next level convenience and more noob friendly. I would advise anyone going tubeless to go straight to the best plug solution. Stan’s Darts are another possible option, but I have never tried them myself. I think I read that someone carried both because the Darts work better in some circumstances and vice-versa. Maybe worth a look, but I’m happy with Dynaplug. I use the Racer tool, which slips easily into a pocket. I keep it in my pocket so I can grab it quickly for instant action. Bacon strips require more preparation, while the Dynaplug tool is locked and loaded!

The U.S. patent enumerated on the Dynaplug instructions I posted above has claims directed to a repair kit, not a plug itself. See 8707829 (uspto.gov)

A Dynaplug repair kit loaded with a non-branded plug may fall within the scope of the claims, but loading a non-branded plug into a Dynaplug repair kit is likely permissible repair with respect to this patent, if the plugs themselves are not separately patented.

I mean maybe, but $64 is vastly more than a basic repair kit plus you got to remember a lot of complete bikes by big manufactures are being sold with tubeless tire standard now. I just had someone approach me about buying one of my bikes and I told them it was setup tubeless and I had to give them a 15 minute dialogue about tubeless and how it works. Do you think every LBS is going to do that let alone mention the bike they have is tubeless let alone it's tubeless and hookless? So yeah to your point yeah you think people buying these more expensive bikes would know what they need or prioritize more expensive tools but I know people that have bought SWORKS or whatever super bike and don't even have a torque wrench...

I dunno. I couldn't find anything on the plug itself. Also, the company was established in 1991. When did the Dynaplug as we know it come into existence?

Anyone who can afford a new bike can surely drop another $64? I’m pretty certain I’ve spent less on plugs than I used to on tubes. Let’s not talk about tyres though 😬

It’s vastly more than a basic repaiir kit but it’s also vastly better.