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-   -   How to build a diesel injector pop tester (http://www.peachparts.com/shopforum/general-information/224334-how-build-diesel-injector-pop-tester.html)

bmwpowere36m3 08-09-2010 09:57 AM

What are you guys using for shut-off valves? The cheapest one from McMaster-Carr rated for 2000psi is ~$35 (4024T71).

cencarnacion 02-05-2011 09:08 PM

Modification
 
I am in the process of building a pop tester based on Cornblatt's design. However, I read in some MB manual that the valve functions to control the rate at which injector pressure increases thus allowing a more accurate reading of pop pressure. I'm thinking that to accomplish this, the sequence should be: bottle jack -- valve -- gauge -- injector. This way the gauge reading will be the pressure at the injector side.

The pop pressure procedure would then be:

1) Pump bottle jack with valve closed.
2) Slowly open valve to increase pressure at the injector side. The gauge should then show increase in pressure.
3) If pressure is not enough, close valve, pump jack and then slowly open valve. Repeat until injector pops.

I will build mine this way and let you guys know how it turns out. The only problem is that I am having difficulty finding 6mm OD Merc injector lines. Another option is to obtain an old delivery valve holder so I can temporarily use one of the injector lines on my 300D. Anyone have a spare injector line or delivery valve holder I can buy?

I have 5 Monark nozzles from C. Sean Watts that I'm itching calibrate and install.

Renntag 03-28-2012 12:54 AM

Quote:

Originally Posted by Archangel (Post 2489972)
Well, let's see.

The welding on the top nut did not go so well.
External Leaks!
RE-WELD!
External Leaks!
RE-WELD!
External Leaks!
Try brazing instead!

No external leaks at all, that is until it got to about 1800 psi, then POP the top blew off where the brazing was with a huge cloud of diesel fuel that sprayed everywhere!

Given your troubles, I might want to go with the portapower design system. No mods.

Oracle12345 04-09-2012 08:30 PM

i tried following this article and I get not pressure at all at the injector so which means i screwed up somewhere. i have no leaks any where but just getting a stream and low pressure. what exactly do we modify to the bottle jack?

bmwpowere36m3 04-11-2012 11:08 AM

Quote:

Originally Posted by Oracle12345 (Post 2917697)
i tried following this article and I get not pressure at all at the injector so which means i screwed up somewhere. i have no leaks any where but just getting a stream and low pressure. what exactly do we modify to the bottle jack?

With the injector hooked up your getting a stream and low pressure? If so then your injector is either dirty/worn/damaged. What pressure are you getting before the injector opens? IIRC, you remove the center ram, weld the pin hole in the inner cylinder, weld a fitting to the top of the inner cylinder and attach a fuel reservoir to the outer cylinder to fill the jack with fuel. There are a bunch of DIYs out there.

whunter 12-27-2013 01:18 PM

Recycled
 
for a forum member

threejak 04-04-2015 01:09 PM

A Macgyver amongst us... Super well done!

240D.Bill 12-01-2016 02:59 PM

Fantastic Write-Up!
 
When I see ones like these it both inspires and intimidates the hell out me from submitting anything half as good. I'm anxious to build one.

Question... Where do you find a shut off valve such as your's that's rated for 3000 psi? I can only find them to 600 at best.

Father Of Giants 09-01-2017 08:54 AM

How much does it cost to build?

optimusprime 09-02-2017 05:34 AM

What about making opne for the old type petrol none electric injectors .Would the idea be the same ?

tjts1 03-20-2018 02:08 PM

Is there an advantage to using a liquid filled gauge vs a dry gauge? My Bosch pop tester came with a couple of dry gauges but I was debating getting a liquid gauge.

vwnate1 02-11-2019 07:01 PM

A Very Good Thread !
 
TTT .


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