Finally fixed my pop tester and built me a set of injectors
 

Anyone have one? It's a Ford Rotunda pop tester I bought a few years from Ebay that came with a Nozzle cleaning kit (made in the UK). The gauge was smashed in shipping and I replaced it with the 6" gauge. The aluminum base is a gallon sized reservoir so it is a stand alone unit which does not need mounting. I think it was a new unit since there was no signs of diesel or oil anywhere when I got it. It worked fine for 2 years and then one day I could not get it to prime and push fuel into the injectors. I tried everything, including filling the high pressure pump plunger cylinder with fuel, to no avail. Finally ditched the reservoir (which constantly leaked diesel past the cover's cork gasket), and gravity fed it with a water bottle via a filter. I had to take the handle off to quickly cycle the plunger to finally get it to prime. I am going to leave an injector mounted when not in use to avoid losing prime again. Maybe I should have done that from the beginning?
http://i31.photobucket.com/albums/c3...806_115946.jpg


This shim kit came in handy. The last set of Monark nozzles I installed went in without changing any of the shims and pop pressures were perfect on all 5 injector bodies. Not so with this set. I am not sure if it is this set of Monarks or this set of injector bodies (bought from Charmalu). I had to change shims(to higher thicknesses) 2 to 3 times to get all 5 set to 2100 psi.
http://i31.photobucket.com/albums/c3...805_171723.jpg

http://i31.photobucket.com/albums/c3...805_174356.jpg
This is the way I test the injector body halves for leak, shaving cream! I did not lap the injectors with grinding compound or sandpaper like a lot of online instructions recommend. If the injector body was not leaking, why lap them? All I did was rub them on a piece of paper with solvent to burnish off the dirt then blow off the lint and clean with solvent.
http://i31.photobucket.com/albums/c3...806_120007.jpg

Painted them with POR-15 to keep the rust in check. I am hoping they will run well and get me better MPG. We shall see.
http://i31.photobucket.com/albums/c3...806_190523.jpg

That looks like your pop tester is on life support.

One reason is that the components will never go back together in the same orientation as they had before disassembly.

It does doesn't it haha? Works great though. No leaks anywhere. The bottle is easy to change and widely available and disposable. The base reservoir held too much fuel and leaked so bad it made a real mess. I can unscrew the fuel bottle without spilling a drop. So much happier with this setup.

Well I have done about 20 injectors now without lapping on a plate, just burnished them with solvent on a piece of paper and have not had one leak yet. What does that indicate? Luck?

Edit: Those mating surfaces have mirror finish on them. That (to me) means they are perfectly flat. If they were not perfectly flat, dirt would get in and they won't be mirror finish throughout and leak. So why lap them? If not lapped evenly, a non leaker will turn into a leaker. Why do extra work?

Where did you get the clear fuel line in the vids?

Nice car.

What vids? :confused:

Thanks for sharing. I made mine from a Ford Rotunda PRV tester (recall) from ebay. See my post. The pump looks like some Australian ones that list >$500. I posted all the PN's I used from McMaster-Carr and shim washers that worked fine.

Interestingly, my 84 300D was running fine w/ 3 or the 5 injectors non-turbo (1600 psi pop). Makes me wonder how important balancing the injectors is.

I saw your post and asked a question on the p/n of a fitting that was n.g. I guess you have not seen it yet? So, with 3 injectors at 1600 psi and the rest at 1900 to 2000 psi did not make the idle rougher?

I like your set up man, who's your favorite ernie or bert?
Glad your back in business.

Huh? I don't watch much TV and not familiar with a lot of programs and their characters. Now that the pop tester is working nicely (hopefully no more problems), anyone in the neighborhood can bring me their injectors for free pop testing. Popping 5 injectors takes about 5 minutes on my setup.

may take you up on that...
 

Hey funola! I may take you up on that at some point - I am in the neighborhood...

Built a pop tester some years ago based on a bottle jack - got some use out of it, but it soon started leaking. Was wondering about the gasket materials in this (cheap, Chinese-made) thing. Do you guys who've built these things typically change out the gaskets?

In any case, injectors tested out fine, and the car has been running smoothly. I suspect I'm due for a nozzle refresh, though, having never replaced them. 400+k miles...

Yeah DrLou, pm me when you are ready.

I installed the injectors and they are running great! Before doing that I popped them one more time by taking slow motion video so I can see the gauge better. At 6" it's a large gauge but the needle fly by really fast and is hard to see. One was 50 psi low so I took it apart and adjusted the shim. Slow motion really help.

Herer's an example video, click to play. Sorry camera was upside down. Is there anyway to flip that in Photobucket?
http://i31.photobucket.com/albums/c3...808_141023.mp4

Here's a video of a new Monark nozzle injector spray pattern. It's a bit wider than a Bosch nozzle.
CLICK TO PLAY
http://i31.photobucket.com/albums/c3...nark5spray.mp4

I have the pressure set to 2100 psi, 50 psi past high end of spec. Hard to say how exact but per the slow mo video of the gauge, I would say +/- 10 psi or better. Engine idles smoother and has a different sound to it. Idle also went up 30 RPM to 680.
Here's a video of it running.
CLICK TO PLAY!
http://i31.photobucket.com/albums/c3...808_161448.mp4

When the injectors were out, I couldn't help and fired up the glow plugs to take this pic.
http://i31.photobucket.com/albums/c3...808_144701.jpg

I popped the old injectors they were all at 1800 psi and had good pattern with no leaks. I also took them apart to see if any pintles were stuck and none were. I could feel the old nozzles had much looser pintles than the new Monarks, which must be due to wear. One of the pintles fell onto the ground and got scratched and would not go back in. If anyone need a set of 4 German Bosch nozzles with 158K miles that are in very good condition I'll make you a good deal. The 5 injector bodies are for sale also. They have no rust and are in very good condition. Or, if you have a new set of nozzles you want me to set up in these bodies please contact me. I'll get some pics of the bodies later.

I was referring to your kiddy pool, the characters are from sesame street...I dont' watch any tv at all anymore but the show has been on the air since 1969, anyway glad your up and running was I was closer I'd take you up on the pop testing.