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Author Topic: Another Injector Pop Tester DIY  (Read 35050 times)

January 06, 2009, 01:10:49 am

Op-Ivy

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Another Injector Pop Tester DIY
« on: January 06, 2009, 01:10:49 am »
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.


Bottle jack with the safety release hole welded shut. This is the hole that prevents the ram from overextending.


Metal plate with fitting tapped into it.


Again.


Initial weld of plate and fitting.


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!


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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1990 TD Jetta - 490,000Km
Reply #1January 06, 2009, 02:59:20 am

Op-Ivy

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Another Injector Pop Tester DIY
« Reply #1 on: January 06, 2009, 02:59:20 am »
Yes. Unfortunately I was limited to a 120v flux core welder.
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1990 TD Jetta - 490,000Km
Reply #2January 06, 2009, 03:37:50 am

Smokey Eddy

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Another Injector Pop Tester DIY
« Reply #2 on: January 06, 2009, 03:37:50 am »
sweet sauce im definitely doing this!
do you have a rough total cost?
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Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
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Reply #3January 06, 2009, 10:27:37 am

Op-Ivy

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« Reply #3 on: January 06, 2009, 10:27:37 am »
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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1990 TD Jetta - 490,000Km
Reply #4January 06, 2009, 11:53:12 am

blkboostedtruck

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Another Injector Pop Tester DIY
« Reply #4 on: January 06, 2009, 11:53:12 am »
Quote from: "Op-Ivy"
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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Reply #5January 06, 2009, 12:43:21 pm

moise

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« Reply #5 on: January 06, 2009, 12:43:21 pm »

 :wink:
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Reply #6January 06, 2009, 04:00:49 pm

Smokey Eddy

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Another Injector Pop Tester DIY
« Reply #6 on: January 06, 2009, 04:00:49 pm »
jesus christ that's a grease gun?
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Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD
Reply #7January 06, 2009, 04:32:08 pm

moise

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« Reply #7 on: January 06, 2009, 04:32:08 pm »
yes, i agree, it's not mine, it 's a exemple :wink:
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Reply #8January 06, 2009, 05:38:41 pm

Vincent Waldon

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« Reply #8 on: January 06, 2009, 05:38:41 pm »
Quote from: "Op-Ivy"
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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Vince

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2001 silver TDI Jetta Malone Stage 1.5 , 2001 blue TDI Jetta SBIII 216s Malone Stage 3, 1970 Bay Window bus

Gone but not forgotten: 1969/1971 Beetles, 1969/1974 Westies, 1979 Rabbit, 1986 TD Jetta, 1992 gas Jetta, 1994 TD Jetta
Reply #9January 06, 2009, 08:33:52 pm

cyrus #1

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« Reply #9 on: January 06, 2009, 08:33:52 pm »
Nicely done Matt!  I look forward to putting it to use.  :twisted:
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Cody

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Reply #10January 06, 2009, 09:53:31 pm

jtanguay

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« Reply #10 on: January 06, 2009, 09:53:31 pm »
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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Reply #11January 07, 2009, 12:48:54 am

Op-Ivy

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« Reply #11 on: January 07, 2009, 12:48:54 am »
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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Reply #12January 26, 2009, 06:53:24 am

Turbinepowered

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« Reply #12 on: January 26, 2009, 06:53:24 am »
Anyone figured out a good source for big gauges? Maybe even ones in Bar? :D
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Reply #13January 26, 2009, 11:43:27 am

dieselherb1

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« Reply #13 on: January 26, 2009, 11:43:27 am »
Surpluscenter.com
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Reply #14February 24, 2009, 11:16:23 am

anto

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Another Injector Pop Tester DIY
« Reply #14 on: February 24, 2009, 11:16:23 am »
Where does the diesel enter this system?
Any pics showing that?
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