Why a new thread on pop testers, when we have a good one by Oldbull in the tech section? Because I wanted to assemble one without welding, opening up possibilities for members who don't have/know a welder.
Parts:
Gauge (use 0-3000 psi)
1/4 NPT to M12x1.5 metric adapter
1/4 NPT F-M-F Tee
1/4 NPT M-M nipple (can be upgraded to a check valve )
Porto-Power or Harbor Freight manual hydraulic pump Use this 20% off coupon
To adapt to an injector, you have two verified options:
1x stock injector line ---OR--- a stock timing ferret adapter and 6mm tube, 2x 6mm tube sleeves, and 2x 6mm tube nuts
Lowest rated part is 3,000 PSI.
NOTE: The 6mm tube nuts will NOT seal directly to an injector. You must use a stock timing ferret adapter OR a stock hard line. Tube/nuts/sleeves NOT required if you use a stock injector line. To fit the tube into the timing ferret, drill out a small cavity for the tube sleeve to fit in, and slightly flare the end of the tube.
POSSIBLE Workaround: Bubble flaring the 6mm tube on the injector side and leaving out the tube sleeve *may* work, but this has not been tested.
Here it is:
Tee fitting forms the heart of the gizmo. The metric adapter allows the use of either a stock line -OR- a 6mm line with tube/nuts/sleeves and a timing adapter.
Why bother? A leaking injector I received from IDIoit dribbled at about 1000 psi... opened it up to find a sliver of metal. A cycle through an ultrasonic cleaner and with the original shim pack it popped cleanly at 2250 PSI (obviously will dial it down).
Q: Couldn't I buy an actual tester for that much? Maybe, but then you wouldn't have a hydraulic porto-power type pump with accessories. They're pretty darn useful to have around. You might find a pump on Craigslist. There are a couple near me for $50.
Q: Why not use a bottle jack? You can, if you can weld. 3/8 NPT Weldable adapter (1/4 NPT is too small to fit the top of a jack) and use a 3/8 NPT to 1/4 NPT nipple instead of the 1/4 M-M spec'd above. I built one using those parts and 2-ton Harbor Freight bottle jack. They (bottle jacks) suck at holding pressure.
Q: Does this Harbor Freight pump hold pressure? Yep, it holds 1700 PSI for a good 5 minutes, and creeps down to 1500 indefinitely.
Q: Can I use plumbing fittings? Absolutely NOT! Plumbing bits are rated to about 300 PSI for brass fittings. The minimum rating of the fittings I've spec'd ranges from a low of 3000 PSI to a high of 6000 PSI.
Q: Why a 0-3000 PSI gauge? McMaster-Carr recommends using a gauge where your operating range is between ~25-75% of the max pressure of the gauge. With a 4-1/2" face and 100 PSI graduations, this gauge is very easy to estimate to the nearest 25 PSI. It's also inexpensive.
Q: Where do I get shims, and how many do I use? I recovered a bunch of shims from junked injectors. A 0.001 shim will change the pressure by about 55 PSI. Use what you need to get a pop pressure of 1850 PSI, +/- 50.
Q: What fluid do I use? Diesel, typically. I'm using WMO cut to 85/15 with RUG, filtered to 1 micron.
Build at your own risk, use at your own risk, don't be dumb, etc etc.
Parts:
Gauge (use 0-3000 psi)
1/4 NPT to M12x1.5 metric adapter
1/4 NPT F-M-F Tee
1/4 NPT M-M nipple (can be upgraded to a check valve )
Porto-Power or Harbor Freight manual hydraulic pump Use this 20% off coupon
To adapt to an injector, you have two verified options:
1x stock injector line ---OR--- a stock timing ferret adapter and 6mm tube, 2x 6mm tube sleeves, and 2x 6mm tube nuts
Lowest rated part is 3,000 PSI.
NOTE: The 6mm tube nuts will NOT seal directly to an injector. You must use a stock timing ferret adapter OR a stock hard line. Tube/nuts/sleeves NOT required if you use a stock injector line. To fit the tube into the timing ferret, drill out a small cavity for the tube sleeve to fit in, and slightly flare the end of the tube.
POSSIBLE Workaround: Bubble flaring the 6mm tube on the injector side and leaving out the tube sleeve *may* work, but this has not been tested.
Here it is:
You must be registered for see images attach
Tee fitting forms the heart of the gizmo. The metric adapter allows the use of either a stock line -OR- a 6mm line with tube/nuts/sleeves and a timing adapter.
You must be registered for see images attach
Why bother? A leaking injector I received from IDIoit dribbled at about 1000 psi... opened it up to find a sliver of metal. A cycle through an ultrasonic cleaner and with the original shim pack it popped cleanly at 2250 PSI (obviously will dial it down).
You must be registered for see images attach
Q: Couldn't I buy an actual tester for that much? Maybe, but then you wouldn't have a hydraulic porto-power type pump with accessories. They're pretty darn useful to have around. You might find a pump on Craigslist. There are a couple near me for $50.
Q: Why not use a bottle jack? You can, if you can weld. 3/8 NPT Weldable adapter (1/4 NPT is too small to fit the top of a jack) and use a 3/8 NPT to 1/4 NPT nipple instead of the 1/4 M-M spec'd above. I built one using those parts and 2-ton Harbor Freight bottle jack. They (bottle jacks) suck at holding pressure.
Q: Does this Harbor Freight pump hold pressure? Yep, it holds 1700 PSI for a good 5 minutes, and creeps down to 1500 indefinitely.
Q: Can I use plumbing fittings? Absolutely NOT! Plumbing bits are rated to about 300 PSI for brass fittings. The minimum rating of the fittings I've spec'd ranges from a low of 3000 PSI to a high of 6000 PSI.
Q: Why a 0-3000 PSI gauge? McMaster-Carr recommends using a gauge where your operating range is between ~25-75% of the max pressure of the gauge. With a 4-1/2" face and 100 PSI graduations, this gauge is very easy to estimate to the nearest 25 PSI. It's also inexpensive.
Q: Where do I get shims, and how many do I use? I recovered a bunch of shims from junked injectors. A 0.001 shim will change the pressure by about 55 PSI. Use what you need to get a pop pressure of 1850 PSI, +/- 50.
Q: What fluid do I use? Diesel, typically. I'm using WMO cut to 85/15 with RUG, filtered to 1 micron.
Build at your own risk, use at your own risk, don't be dumb, etc etc.
You must be registered for see images attach
You must be registered for see images attach
You must be registered for see images attach
Last edited:
