Hi all
After I recently posted a thread asking for advice on using my newly completed pop tester - a member PM'd me asking for pictures and advice on building one.

I mainly followed the excellant DIY by Cornblatt " How to build a diesel pop tester" in the rosource link here a PeachParts.

Used a Harbor Freight 2-ton jack $10. NOTE: Northern Supply jacks wont work for a pop tester because of a differant design.

I bought a 3000psi guage from Lintz - $16 inc. shipping.

I got the high pressure fittings from Wilco in Houston - maker of hydraulic hoses etc. $12

Used a disposable paint cup for a Harbor Freight gravity-feed paint gun $1.50 for a diesel supply container

Made a stand for the diesel supply container from 1/8 X 1/2 aluminum flat bar and two clamps to secure it to the jack barrel. The container was held to the stand with plumbing strap.

Used a Mercedes pre-filter to keep dirt from getting to the injectors being tested. Really, I should have used a finer filter for this.

Bought an injector line from the junkyard $1.50

All in all it was a fun project and is working fine - so far.

Joseph

Attached Thumbnails

     

That looks good! I like the plate under the injector, you may be able to measure the width of the spray pattern with it.

__________________
Grumpy Old Diesel Owners Club group

I no longer question authority, I annoy authority. More effect, less effort....

1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving

I made mine with the 2 ton jack from Northern. Works fine for me. It is identical to yours except its painted red.

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1981 300 SD 213k miles "Stock for now"
1999 Super Duty 7.3L 113k miles
1981 300 SD 180k miles "Heavily modified" SOLD

Hi
I'm glad to hear that yours worked. The jack I bought from Northern had a slot ground into the threads of the top nut instead of a drilled hole for the bypass oil. I couldn't see a way to seal the slot.
Regards,
Joseph

Thanks for the pictures. I have all the gauges and hardware to make a pop tester (have had it for about a year now) but have not purchased a pump.

The only thing that is keeping me from getting a bottle jack versus a hand pump is I don't understand how the tee gets attached to the top of the bottle jack. Can you explain in detail how you attached yours?

Thanks!
Ryan

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2009 ML320 Bluetec
1985 300CD
1981 300TD

Past Mercedes
1979 300TD
1982 300TD
2000 E320 4Matic Wagon
1998 E430
1984 300SD
1980 300SD

Hi
I welded a black pipe bushing to the top nut - giving me a 1/4 inch NPT to fit the high pressure fitting into.

There tends to be a problem welding steel that has had oil soaked into the metal - often leaving little blowholes in the weld area which can leak under high pressure. This can be corrected by a good coating of JB Weld on the underside.

I wanted to drill & tap the top nut so I could just screw the bushing in - but didn't have the needed equipment. There is also a question about the amount of metal avaliable to cut the threads into - since there is an o-ring slot machined into the inside of the top nut..

I hope this helps.
Joseph

Yes, it does help but leaves me with the same dilemna of buying a bottle jack vs. a hand pump. I have a cheap Harbor Freight flux welder. I don't know if I would trust it to do this job. Maybe I'll move up to a nicer welder, get a drill/tap set...or just get a hand pump. We'll see. I'm too busy right now to do either but my schedule opens up in a few weeks, so it will time to do some work I've been meaing to do since fall.

Thanks again.

__________________
2009 ML320 Bluetec
1985 300CD
1981 300TD

Past Mercedes
1979 300TD
1982 300TD
2000 E320 4Matic Wagon
1998 E430
1984 300SD
1980 300SD

I think I'm going to try this one, once I accumulate some more cash:

http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200333147_200333147

Seems like a deal. 1/4" NPT already there.

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1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition

I intended on buying that one awhile ago for the same reason you state but I simply have been too busy to stop in the store and check it out. It does say 1/4" connections but it does not implicitly state the inlet is threaded. Some are not. If you do get it before me, let us know how it works.

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2009 ML320 Bluetec
1985 300CD
1981 300TD

Past Mercedes
1979 300TD
1982 300TD
2000 E320 4Matic Wagon
1998 E430
1984 300SD
1980 300SD

I did one of those chat things and the guy went and checked, he told me NPT.

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1983 240D 3.0T 4-speed manual, now sold

1989 Subaru GL Wagon 5-speed Touring Edition

Graplr I have a decent welder if you need to weld it. I also have 1/8, 1/4, 1/2npt taps.

the pump in the link to NT would have typical 1/4 npt hyd. fittings. that is similar to what sunwizard used, I believe. a nice setup, but to rich for my blood- I'd rather scrounge up some bits at the junkyard and build it.... but thats me.

I have a greasegun type poptester I built years ago and dont really use, but they are great to have.

also- I dropped of a set of injectors straight outta the JY at diesel and import service in blaine- great folks, they teseted out the 5, all were good, and then they wouldnt even take my money..... I had to buy 5 heat shields from 'em just so I could give them something...

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1984 123.193 372,xxx miles, room for Seven.

1999 Dodge Durango Cummins 4BTAA 47RE 5k lb 4x4 getting 25+mpgs, room for Seven.