I have been gathering information from various threads about building my own injector pop tester. It seems that the best way to go is with a hand pump (not a bottle jack due to the welding/drilling involved). I've read a few threads where people have used the Torin Big Red T71101 10 Ton jack.

For more information on this (and to help others wanting to build their own), take a look at this thread posted on a VW forum.

VWDieselParts.com • View topic - List Your Homemade VW Specialty Tools Here!!!!!!!!

Scroll down until you see the post about the injector pop tester. Has anyone done it this way? The "1/8" male x 3/8" Female pipe adapter (the brass fitting between the T and pump)" is obviously brass, which cannot withstand much pressure. The one I found could withstand about 500 PSI from McMaster.

This does seem like a good setup, but again I am unsure about that fitting, as well as trying to make the fuel filler side work. I just wanted to see if anyone has done this so I can get a better understanding on how exactly to go about making this work correctly.

Thanks

I haven't personally tried it, but I believe this is also what Kent from Mercedes Source uses with his kit.

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"Time's never wasted when you're wasted all the time"

I recently set my pop tester up with a porta-power replacement unit from fleabay. $60. w/free shipping. A bit more expensive than a bottle jack but time is money and I made no mods to the pump. No welding or JB Weld . I like the long hose so I can place the injector wherever I want. (I also used high pressure fittings from Fastenal to make the connection from the unit to the injector line.)

I made no mods to the pump so there is no reason to believe it would blow apart....I filled the hydraullic fluid reservoir with calibration fluid...plenty of volume to test a bunch of injectors and I can refill it if needed.

It's a 10 ton ram (think that's enough pressure?? )

Porta Power Replacement Hydraulic Pump Lever 10 Ton 20 000lbs RAM Frame Machine | eBay

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1985 300D 172,110mi and goin' strong

Thanks for your input. You were able to connect the injector line to the rubber hose attached to the pump? What fitting did you use? Also, do you not have a line coming from the other end of the pump for the fuel supply?

I've never heard of anyone using "calibration fluid". Only diesel and WVO or SVO. I'm just confused how you're filling the pump without constantly having to refill it without a line going to the fuel supply.

Yes, I was able to make the connection from the rubber hose to the injector line. Drop by Fastenal and they'll help you mate it. (Reminder, be sure to ask for high pressure fittings!)

As for the calibration fluid, I called a local oil dealer and asked. I don't have the specs with me but I believe it waseither DELPHI or CASTROL CALIBRATION OIL 4113 (good for calibration and storage of injectors....also less toxic and less flamable) You cn buy it on-line for 40/gallon and a gallon will last you a long, long time. OR drop by a injector shop talk nice and be open to learning then offer him $15 bucks to share some with you. That's what I did.

Yes, most use diesel fuel...I'm a bit paranoid.

I haven't had to refill the pump when I'm pop testing. I do (re)fill it before I start... the body of the pump holds a fair amount and I've never run dry.

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1985 300D 172,110mi and goin' strong

I've never thought about just filling the pump instead of having a reservoir. I'll have to try that. Were you able to do all five injectors with one fill?

I'd really like someone who has the Torin Big Red pump to chime in on this thread. The link to the thread I posted above says the threads on the pump are 1/8" but I just chatted online with Home Depot and they are saying the threads are 1/4". Not sure who to believe but I'd like to get it sorted prior to purchasing all of the parts online.

Yup....there was enough in the reservoir to do five and then some. When I did it, two of the injectors needed a fair amount of tuning requiring a fair amount of testing.

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1985 300D 172,110mi and goin' strong

After reading all the pop-tester threads, I must build a pop tester now.
I have a military version of the porta-power pump that is more than enough to get 3000 psi. I have a few Ashcroft 1279 gauges laying around too. This is going to be fun.

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1986 560 SEL
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1970 Cougar XR7
2002 Crown Vic Sport
1992 F150