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Message: [QUOTE="Cold Roller, post: 637020, member: 9551"] I measured another set of injectors this morning. The intensifier bore depth was out slightly on some of them. I had similar results on the first set as well. Lilpooh shows 0.029" as the space available, but I had a few that were as tight as 0.025". It would be a good idea to measure the shims to see if they are different thicknesses as well to make up for the bore depth. Most of the ones I have seen are within 0.002 of each other. After thinking about it a little longer, it is probably a good idea to leave a minimum of 0.005 as a buffer for the plunger to fuel plate clearance. So what ever you cut from the intensifier piston, cut 0.020" less off the plunger. I would cut 0.035" max of the hammer end of the plunger, and cut the remaining amount from the clevis end. So in the previous post, the chamber would need to be 6.63mm deep to keep the plunger safe from bottoming out. and the total stroke would be 6.5.mm. Again, keep in mind the plunger in a stock injector sits about 5.6mm from the fuel plate at rest (volume 177ml) but does not travel full length (loss of 22ml) and looses some out the spill port to give about a 135 injector. This is why a simple plug give you a 155cc injector. This is also why you don't necessarily need to cut 2.21mm off the intensifier piston to achieve the desired travel. You could, but it is not as efficient as moving the plunger down the bore. I initially said about 1.55mm cut, but it could be up to 1.9mm or even 2.2mm, depending on how much spill you are willing to take. Again, keep in mind that you are reducing the plunger by a smaller but similar amount and it will increase the resting point further above the spill port. [/QUOTE]

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