The ABC Motsepe League team were hoping to claim a third top-flight scalp (after wins over SuperSport United and AmaZulu in the two previous rounds), but they fell just short of taking down the Buccaneers.
After a tight first half in which both teams struggled to create clear chances, Pirates claimed the lead 10 minutes into the second stanza after Thembinkosi Lorch started a move from deep, combined with Kermit Erasmus and thumped home.
Yet Dondol came up with an almost immediate response, as Tebogo Makungo ghosted past several defenders and headed home from a corner kick for 1-1 in the 57th minute.
Bucs looked the likelier scorers in the rest of regulation time, as Nkosinathi Sibisi hit the post and Bandile Shandu forced a great save from Stars goalkeeper Sphamandla Gumede.
Pirates kept up the pressure through extra time, with Lorch notably missing a sitter, while Dondol almost scored a stunning last-gasp winner via Makungo from long range, but Sipho Chaine palmed over the crossbar to send the game to penalties.
The first four rounds of kicks were successful on both sides, before Dondol’s Whitehead Nameka had a weak shot that was easily saved by Chaine, allowing Pirates’ Sandile Mthethwa to convert the decisive kick for a 5-4 triumph.