Another Pop tester build

[DougBoy66]

I had been looking to get a Pop tester. Seemed like all the ones that can be bought are iffy. If this is old news I apologize.

SO, I read up on OLDBULL8'S bottle jack build. It is great. I am just very novice at welding so, I kept looking at video, threads and PDFs. So I came up with this no-weld (other than JBweld)bottle jack type tester after combining some of what I thought were the best things that each different ones had done

I made up a list of parts and got to it. First a 2 ton bottle jack. Has to be the thread on top type. Not welded.

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So I disassembled it and drained all the jack oil out and removed the ram, I did not use it for this build. Next I threaded the inside of the stand pipe with a 3/4npt tap

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Also had to drill the hole in the cap nut out to1-1/16 (slightly larger than the OD of a 3/4" pipe)

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I inserted a 3/4" x 2.5 inch nipple into the now threaded inside if the ram tube. I am just test fitting at this point.
There are bleeder holes in the cap nut that I tapped and inserted allen set screws with JB Weld on the threads and over the hole areas

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[DougBoy66]

Part 2
Here is a couple pictures of my nice JB Weld work

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I put it together and apart a few times to make sure where I could put the JBW were it would not interfere with final assembly. Then very unlike myself I stopped and let it cure fully.
After everything cured I started putting it together. I used a generous amount of Teflon tape on each threaded fitting. A 3/4" female to 1/4" on top of the nipple coming out of the top of the jack, a 4 way 1/4" cross, some 1/4" nipples a valve to relieve pressure if need and a glycerine filled 3,000 psi gauge.

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After this I reduced the injector side 1/8" npt and used an old injector line that was cut so that it would hold the injector level held in place with a ferrel fitting(cleaned up the fuel line with some fine emery tape)

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On this jack that bought the fill hole in the back was threaded for 1/8" npt so I used a couple fitting, a 90 elbow, fuel filter, a couple of pieces of fuel line and clamps for the filling. Also a glass jar to view the pop. I have an old injector for testing. It popped at about 1550 psi and leaked by before resetting. It did hold at 1000 psi without fading so I am pretty confident everything is leak free internally as well as out

 

[DougBoy66]

One thing I wish I could have done would have been to be able to use an o-ring to seal between the top nut and the nipple that goes though it. That is how the ram originally sealed but, after dilling the hole in the cap nut larger It would require some machining to make the o-ring groove deep enough.
What is not pictured because I did it after I was sure it didn't need to be broken down to fix any leaks, I put JBWELD around the seam between the top nut and the 3/4" nipple that passes through it so I can put a small fuel container above the filter where the funnel is in the picture. As it was, I couldn't fill it with fuel above the top of the top nut because it wasn't sealed yet. I am sure I came in cheaper that the ones available online.

 

[Danielle]

Then very unlike myself I stopped and let it cure fully.

Are we twins?

Thank you for posting this! I just broke out an old tester that's been sitting and it is so far gone I knew I wouldn't have the brains to repair it.
This looks like something I can do and I have a lot of mentioned parts probably laying around!

 

[DougBoy66]

Are we twins?

Maybe!?

Thank you for posting this

No problem. It definitely wasn't all my own brainstorming. To be honest I just borrowed from what I thought were the better parts of what a few other people on the web did. There are probably plenty of improvements that could be done

 

[Jesus Freak]

Great job, senor.

 

[DougBoy66]

Great job, senor.

Thank you!

 

[Old Goat]

Great job, looks professional.

Someone posted on one they bought on line couple years back.
It wasn`t washed out very well, still had some stuff from the machining.

There are people on the side lines reading this.
NEVER PLACE ANY BODY PART IN THE STREAM FROM THE INJECTOR SPRAY.

It can and will inject right through your skin.
It cannot be flushed out. The part will need to be amputated.

If Iam remembering right, a correctly adjusted Injector, puts out
something like 1800 PSI.


Goat

 

[DougBoy66]

Goat is correct on the pop pressure and the danger of the diesel injecting through the skin. That is why I have the glass jar to be able to see the pattern and to protect from the spray. Thank you Goat for adding that.

 

[Nero]

Hydraulic injection wounds are nothing to take lightly.

Also, I have this bad boy, just need an adapter. Doesnt look as cool as your bottle jack though.

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[DougBoy66]

Nice! @Nero I have a picture of something like that in the service manual. I like yours

 

[Nero]

This is an OTC one I've had for years, pretty sure it needs a new calibrated gauge. Maybe a fluid flush.

 

[DougBoy66]

Here are some pages from the manual. Not the greatest pictures

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[Nero]

I am also an average fuzzy text enjoyer

 

[u2slow]

I didn't have enough of the pieces laying around to build... so I bought the vevor. Paid for itself already.

Darn handy tool to have around!