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General Information => FAQ/Tech Tips/Please Read First => Topic started by: Op-Ivy on January 06, 2009, 01:10:49 am
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So I finally decided to build a pop tester. I've been wanting to replace the nozzles for a while.They are still the originals!!! :shock:
I took some pictures while making it so I thought I would share them. There are a couple good DIY's on the forum right now but another one will help clarify things a bit.
Nearly all of the parts, minus the injector line that was bought from Vincent Waldon, were purchased at princess auto.
Materials used:
2ton Bottle Jack
0-3500PSI Gauge
Steel hydraulic fittings rated at 5000 psi
Here you can see the entire contraption laid out. Note that I had to use two adaptors, one from the injector line to an awkward thread type I can't remember the name of, and then another one to NPTF.
(http://i96.photobucket.com/albums/l163/Op-Ivy/Injector%20Pop%20Tester/P1040004.jpg)
Bottle jack with the safety release hole welded shut. This is the hole that prevents the ram from overextending.
(http://i96.photobucket.com/albums/l163/Op-Ivy/Injector%20Pop%20Tester/P1040001.jpg)
Metal plate with fitting tapped into it.
(http://i96.photobucket.com/albums/l163/Op-Ivy/Injector%20Pop%20Tester/P1040002.jpg)
Again.
(http://i96.photobucket.com/albums/l163/Op-Ivy/Injector%20Pop%20Tester/P1040003.jpg)
Initial weld of plate and fitting.
(http://i96.photobucket.com/albums/l163/Op-Ivy/Injector%20Pop%20Tester/P1040012.jpg)
Pop tester completed. I ended up having to really load on the welding wire. At first I had a few "weeps" of fuel coming out. Works great now!
(http://i96.photobucket.com/albums/l163/Op-Ivy/Injector%20Pop%20Tester/P1040016.jpg)
Hope this helps anyone else thinking about making one. Not shown is the steel plate shield I made to prevent injury in case of any failure of parts.
If anyone has any questions, feel free to ask! :)
Matt
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Yes. Unfortunately I was limited to a 120v flux core welder.
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sweet sauce im definitely doing this!
do you have a rough total cost?
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Total cost minus welding wire which would be too hard to calculate would be about $50.
Time to build was an afternoon and a bit after dinner.
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Total cost minus welding wire which would be too hard to calculate would be about $50.
Time to build was an afternoon and a bit after dinner.
you should of sent it to me to weld i could of made it look like a 400dollar weld! :D oh well next time! a bigger gage is always better like a big 5" round gage with lots of marks for finer adjusting! you got shims?
Duane
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(http://img293.imageshack.us/img293/9820/dscn1308dy7.jpg)
:wink:
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jesus christ that's a grease gun?
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yes, i agree, it's not mine, it 's a exemple :wink:
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Total cost minus welding wire which would be too hard to calculate would be about $50.
Time to build was an afternoon and a bit after dinner.
Great job... of course I think the injector hard line is the best part, but that's just me ;-)
One thing I did before I filled it the first time was drill four mounting holes in the base so that I could screw it into the workbench. It actually takes a bit of handle pressure to generate 155 bar and I discovered having the thing securely fastened down was as simple as some #12 wood screws thru some freshly-drilled mounting holes.
On a related note.... I made the mistake of prematurely shortening the handle (to save workbench space) ("how tough can this be") and I now have to reef on mine pretty good to generate pressure. Or perhaps I'm just a wimp. :wink:
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Nicely done Matt! I look forward to putting it to use. :twisted:
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make sure to use it slowly when nearing the breaking pressure for better accuracy :wink: the longer the high pressure line, the more inaccurate result if you don't do it slowly.
good setup!
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Thanks for the tip Vince! I actually just clamped it down to the workbench with a C clamp for the time being, but thats a good idea.
Dwayne, I still haven't contacted the group buy vendor for nozzles yet. Just waiting for paypal to receive my deposit. But yes I will need shims and heat shields.
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Anyone figured out a good source for big gauges? Maybe even ones in Bar? :D
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Surpluscenter.com
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Where does the diesel enter this system?
Any pics showing that?
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Hey, i have access to a standerd injector pop tester at work but it is designed for standard fractional style injector sizes... My question is what is the thread size on the vw injectors so i can get the right sized fitting
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Where does the diesel enter this system?
Any pics showing that?
In the last picture, under the plate in the cylinder. Between the outer and inner cylinder. That is what you fill.
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Thanks op-ivy, its just i saw other pop testers with a reservoir built in, but i gather it doesnt matter and people only do that for ease of refilling.
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I just took Andrew's idea and used a tranny fluid bottle. and filled it with clean diesel. Works great!
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Hopefully have mine working tonight all being well, il post a few pics once im happy with it....
Thanks,
Anton
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Here's the one I recently finished. I got lucky on the gauge.
My injectors were suppose to be set to exactly 155 bar. But their not. (2050 to 2150 psi) 155 bar=2248 psi. Assuming this gauge is accurate (it was calabrated in 1987 then set on a shelf till I bought it on E-Bay)
Guess I'll buy some shims and play around.
Any Tips on cleaning, etc?
(http://i256.photobucket.com/albums/hh177/AudiVWguy/IMG_1858-1.jpg)
(http://i256.photobucket.com/albums/hh177/AudiVWguy/IMG_1852.jpg)
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Some pics of my DIY pop tester;
(http://i265.photobucket.com/albums/ii209/doodaa306/poptest.jpg)
(http://i265.photobucket.com/albums/ii209/doodaa306/poptest2.jpg)
Just need to cut a hole in a jam jar top to contain the spray and diesel mist and im done.
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Just wondering should my tester be able to hold the pressure and not let it drop off in between strokes of the handle?
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Just wondering should my tester be able to hold the pressure and not let it drop off in between strokes of the handle?
it would be best. is the injector leaking at all? you should be able to bring the pressure right up close to the breaking pressure and the injector should not leak. i think theres even a small amount of time you're supposed to hold it at that pressure to make sure it doesn't leak/dribble.
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Injector doesnt leak, so its not losing pressure there, i think it must be the way i have made it, i just dont know whereabouts i have went wrong!?
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A couple of possibilities:
* the little one-way valve built into the base of your bottle jack is not holding the pressure. Bottle jacks are pretty cheap and this happens sometimes... I'd probably just buy another one and swap out the welded parts with a new base. Did the jack hold weight before you took it apart?
* you forgot to weld over the small bleed hole at the top of the ram tube... it's there to keep the ram from pushing out the top of the jack but will let out pressure when the jack is turned into a pop tester.
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A couple of possibilities:
* the little one-way valve built into the base of your bottle jack is not holding the pressure. Bottle jacks are pretty cheap and this happens sometimes... I'd probably just buy another one and swap out the welded parts with a new base. Did the jack hold weight before you took it apart?
* you forgot to weld over the small bleed hole at the top of the ram tube... it's there to keep the ram from pushing out the top of the jack but will let out pressure when the jack is turned into a pop tester.
Vince i welded over the little pinhole so i dont think it is losing pressure there.
However where you had a hole in the top large nut that could be welded, mine has a channel perpindicular to the threads, which i assume led to the pinhole.
Could this be where im losing pressure?
Thanks for the help guys, il get there in the end.... :)
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Just in case it is of use, for those who like playing with high pressure hydraulics in Devon,
http://www.teignflex.co.uk/ (http://www.teignflex.co.uk/)
They are lurking at Heathfield near Bovey Tracey just off the A38.
They do compression fittings for 6mm pipe and several hundred bar which is PROBABLY the right size for VW injection pipes, as well as for those weird BSPT fittings for pressure gauges, but Iwill let you know how I get on with mine. ;)
Success! or amputation. :P
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I figured a simpler way to do it:
(http://www.triny.eu/marco/DSC00921.JPG)
I had the machinist make me a thread on the top nut, its 3/8", then an 3/8 to 1/2 adapter, then a 1/2 to male 1/4", then the T fitting.
also took a 1.9TD delivery valve to be cut into 1/4" thread (not seen done yet)
welded the pinch hole on the cylinder, used a M5x0,6mm bolt on the big nut.
enlarged the side hole on the external cylinder and fitted a 1/8" fittin and nut on the inside.
to do:
-filters (inlet and prior to the big nut)
-bracket for a cup and a small transparent hose
-jar with lid for keeping the diesel vapours out of my lungs
-use sealant on the threads and tighten everything down, if it leaks I'll weld it all around (simple weld compared to those shown)
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Ok, I cheated. "Injection Tester" on Fleabay, for £80, so will save me a load of fagging about with a lathe, welding (JB of course ;D) and assorted taps and picking swarf out of my fingers. So I am now the proud owner of a Citroen Suspension Sphere Tester. DOH! ::) Close, but definitely no cigar. Of to read the small print on Ebay. :P
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So I am now the proud owner of a Citroen Suspension Sphere Tester.
Hey, I could use that, since I have a DS19 in my garage taking up space....
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I have a DS19 in my garage taking up space....
I am SO jealous ;D