injector hole profile

[SLangegger]

does anyone know if the holes in a 2003 ho injector have a curve or are the holes straight thru? how are they manufactured? do you think the holes could be opened up using wire e. d. m. ? thanks for your help

 

[rbattelle]

I'd say they're straight. Check out the injector pictures in this thread:



https://www.turbodieselregister.com/forums/showthread.php?t=108324

 

[KERMA]

does anyone know if the holes in a 2003 ho injector have a curve or are the holes straight thru? how are they manufactured? do you think the holes could be opened up using wire e. d. m. ? thanks for your help

wire EDM is part of the manufacturing process.



You won't have to modify nozzles at all by either EDM or honing, soon...

 

[R.M.THOMPSON]

Hey KERMA,

Give us a little more to go on than that

 

[KERMA]

In due time. Ask the VW TDI guys...

 

[SLangegger]

do you think that a qualified machinist/wire operator could fixture and cut thier own injectors? I am assuming when you read about edm injectors they are talking about wire edm. I cant see making an electrode small enough to burn using conventional. Just looking for opinions. Why spend $1100 if I can do it myself. But at the same time why waste my time making scrap!! Thanks for your input



Steve

 

[KERMA]

THere is a big difference between 6000 psi and 28,000 psi. The common rail stuff is definitely NOT something most machinists could make, at least so it will last. We are talking making sub-micron (ten-thousanth to hundred-thousanth) tolerances, heat treating, using the right alloys, and doing it consistently. It is a very specialized area of manufacturing. Even Bosch has trouble making the stuff right. Look at all the trouble the Ford and Chevy guys have experienced with their OEM common rail stuff. 28,000 psi is a lot of pressure.