HOW-TO: Rebuild Diesel IDI Injectors
 

A fantastic DIY link. :D
http://vincewaldon.com/index.php?option=com_content&task=view&id=20&Itemid=28

Well there goes all my buisness. :rolleyes: :D

I just glanced throught it, but it seems to be fairly complete. I also wire-brush the inside of the lower body, then clean with solivent and blow it out with an air gun. Some really nasty crud accumualtes in there.

I would say that just using lapping compound on the Glass Plate is better than using various grits of Emery Paper on top of a Glass Plate; the Glass Plate by itself is much falter than Emery Paper over the Glass Plate.
Rock Shops can supply suitable lapping compound fine enough to do the job.

Hmmm... My school's shop has a .00001" flat granite table....

I do not think they would be happy with you lapping on it; and a plate of glass is easier to take home:)

I use a plate of glass and 600 grit lapping compound I bought from a Rock Shop supply seller on Ebay. (They use the compound to tumble Gemstones and Rocks to smooth and polish them; as well as to lap flat surfaces on them.)
If I was in a hurry I'm sure I could have found a local place to buy the compound from.

One of the members balked at my use of 600 grit; but we used 500 grit on a Cast Iron hand lapping plate and the Lapping Machine at the Fuel Injection Shop I used to work in.
I have rebuilt 4 sets of Injectors using the Glass Plate with no problems with leaks.
I would like a regular lapping plate but keep getting out-bid on Ebay or the shipping of the heavy plate is too expensive.

I use 2000 grit

Don't worry the Bottle Jack Pop Testers have worked for some but not all who have made them.
It also might help convince folks that is really not a good idea to just take the Injector apart and Swap the Nozzles.

Recycled
 

for new members.

Pop tester build
 

I built this one, with a variables such as a 6" face 3000psi gauge, but the basic premise works, and it can be done inexpensively with a little patience.

How to build a diesel injector pop tester - Topic

I've done 3 sets of injectors with it. It takes a little use to get comfortable with setting the pressures, and a stout bench vice next to it makes the process a lot easier. The vincewaldon site is invaluable for getting into this process.