i was reading on power stroke nation that the 238cc hybrids use a 530 barrel and plunger out of the BD injector that is a 7.1mm plunger were the AA code is a 6mm and then you can put the AC intensifier piston that is at 29.7mm in length and the factory AA code injector piston is 32.2mm, from what i have gathered between the 530 barrel and plunger and the AC intensifier piston i should be up and around the ~230cc area, if this is correct, to do this do you use all 3 internal o rings out of a AA code injector, also what i have gathered if you just put the AC inten piston in a AA injector it gets you to a ~160cc then you add the BD barrel and plunger it turns it into a hybrid do to the larger fuel dilivery with the same amout of oil used.

is the only parts needed are the barrel and plunger, intensifier piston, the 3 internal o rings, and a external o ring kit, then find nozzles to replace my old ones, with the nozzles would i be able to run a B series nozzzle and what one would be a good one to run.

i know its not an easy task but i would like to find an old injector and tear it down and study it and see what all is in it before i go spending the money on all the parts any knowledge would be greatly appreciated

 

Basically, you're correct.
But you do NOT want to run B code Nozzles. Only 7.3.

However: To atually get the full 238 cc of flow there is other machining, porting, and flow matching needed with an injector that big. This is why I stopped selling the Stage-3 DIY Kits a while ago. It's not really a DIY project without the proper machining, porting, and flow matching.

And no, I won't go into detail of what exactly is done. If you want the best possible Hybrid set, have a shop build them for you.
If you want to risk having a massively unballanced, poor flowing set of injectors, then try it yourself.

I urge you to find a spare injector and take it apart and learn how they work.

 

well i decided i am just going to put intensifier pistons in to make them a 160, any one know were i can get all the tools to disassemble the injector and assemble them and also can you removed the screws by drilling them out with a drill bit or do you need a special bit like jim is having designed, is the 4 screws that hold the solenoid on, the adjuster screw or the 4 assembly screws that get drilled out. (jim do you have any of the tools you would sell out of the diy kit or are you out of them till you get the bits built and ready to go)

 

Solenoid and Adapter screws are just regular Torx.
The Armature screws take a special bit.
I'm closed on Friday's, shoot me an email next week and I'll see what I can do.

Jim
sales@rosewooddieselshop.com.

 

i am guessing you also need that special bit to intall the screws to