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Old 08-09-2010, 09:57 AM
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Location: Shelton, CT
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What are you guys using for shut-off valves? The cheapest one from McMaster-Carr rated for 2000psi is ~$35 (4024T71).
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Old 02-05-2011, 09:08 PM
Join Date: Nov 2007
Location: Houston
Posts: 31

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.
87 300 SDL , 84 300D, 95 Nissan Quest GXE, 06 Honda Odyssey Touring, 03 VW Jetta GLS TDI
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Old 03-28-2012, 12:54 AM
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Originally Posted by Archangel View Post
Well, let's see.

The welding on the top nut did not go so well.
External Leaks!
External Leaks!
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.
83 300TD (need rear wiper assembly dead or alive)
85 300TD almost 400k miles and driven daily.
98 E300D *sold
86 300SDL *sold and made flawless 10 hour journey to new home.
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Old 04-09-2012, 08:30 PM
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Location: USA
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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?
1986 300SDL, 211K,Dealership serviced its whole life
1991 190E 2.6(120k)
1983 300D(300k)
1977 300D(211k)
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Old 04-11-2012, 11:08 AM
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Originally Posted by Oracle12345 View Post
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.
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Old 12-27-2013, 01:18 PM
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for a forum member
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Old 04-04-2015, 01:09 PM
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A Macgyver amongst us... Super well done!
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Old 12-01-2016, 02:59 PM
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Location: Vancouver, WA
Posts: 114
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.
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Old 09-01-2017, 08:54 AM
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How much does it cost to build?
1986 Mercedes 300SDL Black - 320,000 miles. Out of retirement

1997 E300 Captain Slow - 218,000 miles

2000 Mercedes E320 Black - 136,000 miles - New daily driver.

Don't forget to grease the screw and threads on the spring compressor.
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Old 09-02-2017, 05:34 AM
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Location: Worcestershire in England
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What about making opne for the old type petrol none electric injectors .Would the idea be the same ?
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Old 03-20-2018, 02:08 PM
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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.
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Old 02-11-2019, 07:01 PM
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Thumbs up A Very Good Thread !

1982 240D creampuff 370,000 miles
1978 300CD back from the dead&1980 300CD ~ SOLD
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Posted By For Type Date
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