Torquay 0 - 1 Crawley Town
Crawley missed two penalties but still edged out League Two Torquay to become the first non-league side to reach the FA Cup fifth round for 17 years.
Matt Tubbs put the Blue Square Bet Premier side ahead with a neat finish.
Gulls keeper Scott Bevan kept his side in the game by saving a Tubbs penalty after Chris Zebroski was sent off.
Bevan repeated his heroics from Craig McAllister's spot-kick before Crawley had Dean Howell dismissed but Torquay could not force an equaliser.
Kevin Nicholson crashed a long-range volley against the top of the visitors' bar in the closing minutes but Town, who have already shocked Derby and Swindon this season, held on to continue their remarkable run.
Only five other sides from outside the Football League have reached the last 16 of the Cup, and none have made it this far since Kidderminster Harriers in 1994.
Having spent more than £500,000 on players last summer, Crawley can hardly be classed as minnows but they have still punched way above their weight and this kind of performance means no-one will relish pulling them out of the hat in Sunday's draw.
Torquay were trying to create their own bit of Cup history too, having never been beyond round four in their 111-year history, but missed out despite Bevan's best efforts.
After kick-off was delayed because of crowd congestion, Torquay went closest to scoring in a cagey opening 30 minutes, when Danny Stevens saw a fierce shot from the edge of the area swerve a fraction wide.
But Crawley had been enjoying plenty of possession too and Tubbs fired over from close range before making up for missing that chance by finding the net in the 39th minute.
Bulman chipped a ball into the area and Tubbs was first to it, turning to send the ball dipping over the advancing Bevan and into the corner of the net.
The Gulls started the second half well and came within inches of an equaliser when Stevens was unable to turn home Zebroski's low cross.
But the visitors should have been home and dry soon after when Zebroski was shown his second yellow card in the space of 60 seconds for a handball in the area and referee Darren Deadman pointed to the spot.
Bevan kept Torquay's hopes alive in spectacular style, however, when he plunged to his left to keep out Tubbs' penalty and amazingly the goalkeeper was to deny Crawley again seven minutes later.
This time it was McAllister who stepped up after Lee Mansell fouled Jamie Cook but Bevan dived to his right and somehow tipped his effort over the bar.
Torquay's 10 men poured forward and Stevens went close with a cross-shot before the game took another twist when Howell also saw red following a melee.
That left the Gulls with 10 minutes to find a leveller but Crawley held out, leaving their 1,200 travelling fans to begin their celebrations at the final whistle and also start thinking about who they want to face in round five.
http://news.bbc.co.uk/sport2/hi/football/fa_cup/9379079.stm
