DIY Boost leak tester guide

rsmith

Robbie
Apr 28, 2004
2,797
1
Tipperary, Ireland
Hello all,

Here is a guide I promised on how to make you own Boost leak tester from readily available items currently on the market. This is my latest version and works perfectly.
There are a few variations of these on the internet ranging from a tennis ball to a tin can, there not really that successful though. I made this as i have a lot of mods on my car and i wanted to be sure everything is was as it should be, boost leaks are little ba$tards to track down and the approach of replace every pipe in sight didn't sit well with me.So far before this i have diagnosed a faulty forge DV relocation hose(Forge replaced ASAP upon seeing the video)

Also please bare in mind this is for a 1.8t that uses 60-63mm boost hoses, you can get bigger/smaller pipes to suit other models, also use of a compressor is needed( or pop down to the local garage and use there air!)



What you will need


1.Tire value stem. http://www.jegs.com/i/Billet-Specialties/1...oductId=1256859 http://cgi.ebay.co.uk/4-x-Chrome-Tyres-Val...=item3a599ff168
2.PVC(wavin) 63mm OD pipe(called 2 inch wavin in most plumbing places)
3.PVC cap for pipe
4.PPFE aka plumber tape

Optional
5.PSI pressure guage http://cgi.ebay.co.uk/50mm-Pressure-Gauge-...=item3a5ac915aa
http://www.amazon.com/Ametek-0-30-General-...463&sr=1-11
6.Expoxy resin for beading the pipe.(any hardware store, a cold weld will also do)

DSCF1622.jpg




Cut the PVC to desired length, i cut miner to about 5" so i could get it into the IC pipe work nice and snug.
DSCF1628.jpg


Then drill two holes in the top, one for the PSI gauge and one for the Valve stem. Make sure to measure twice and drill once, i drilled mine slightly smaller and let the guage
self tap itself,(tip, if you find it hard to get in, gently heat the plactic with a lighter) i also used PPFE tape(plumbers tape) around the threads on the valve stem and guage.
Also make sure to sand down the drilled holes so they are nice and smooth.
DSCF1626.jpg

DSCF1637.jpg

Inserting the Valve stem, you can use the rubber push in valve stem or the bolt in ones, I used the bolt in stem as i had one available.

With the Push in rubber stem, simply drill the hole to the same size as the lip in the rubber stem, they should be self sealing.

For the bolt on, simply drill the hole the same diameter as the lip in the rubber part of the bolt, insert and tighten.

Its the same for the PSI gauge.

DSCF1629.jpg

DSCF1632.jpg



When you have the PSI Gauge and Valve stem inserted, simply put the cap on the PVC pipe, push it in as far as it will go, you should add a small
bit of glue if needed and it should seal itself very tight, if it does not create an air tight seal, use some silicon that you can get in any store, woodies etc.


DSCF1638.jpg



Optional:

In my guide i put some epoxy resin around the end and left it harden, this is simply there to stop the tester blowing off under pressure.

DSCF1643.jpg



This is what it will look like when interested into you boost hose and the clamp tightened.
DSCF1649.jpg


And finally some vids of how to use it.
I hope you all find this beneficial is diagnosing those pesky boost leaks that rob us of power, smooth running and generally give us a pain in the backside.






@Mods please move this to what ever section you feel it better fits if needed.


P.S 22seconds into the first vid i meant to say, "compressor" not "generator", my bad :-(

Part 2 of the video is below:
 
Last edited:

sambryant

RoadRunner meep meep
Mar 26, 2009
4,847
2
Bristol
rsmith, what a fantastic bit of kit. i have just orderd every thing i need from the internet inorder to make it.
i have suspected a leak for a while now, so this will confirm it :D
thank you for the guild and thank you for saving me time and money :)
 

sambryant

RoadRunner meep meep
Mar 26, 2009
4,847
2
Bristol
well well well. all my bits arrived today to make my boost leak tester. so here is some pics of my
10 min effort :)

 

Murdered LCR

Wide mouthed mofo
Sep 9, 2006
6,646
8
Murder Inc.
Looks good just make sure you take the oil cap off and do it through the top intercooler hose as going through the tip can pop the turbo sills
 

sambryant

RoadRunner meep meep
Mar 26, 2009
4,847
2
Bristol
the whole thing cost around £10 :) i have tested the unit by blocking off the end and pumping it up by hand and works perfectly. tomorrow will be the real test hehe.
thanks rsmith for the guide, also loving your engine bay :)
 

rsmith

Robbie
Apr 28, 2004
2,797
1
Tipperary, Ireland
the whole thing cost around £10 :) i have tested the unit by blocking off the end and pumping it up by hand and works perfectly. tomorrow will be the real test hehe.
thanks rsmith for the guide, also loving your engine bay :)

No worries and thanks, as long as the guide helps someone, personnally i think if you have a Turbo charged car with a lot of mods a leak tester is a must. Leaky pipes is what drove me to make one of these.
 

S3 Nattie

Active Member
Sep 10, 2009
120
0
Very good little guide.

Just wondering though, does going through the in hose in the video pressurise the all the pipes, even the pipes under the inlet manifold or is it just the boost pipes

Nathan
 

Henk80

Guest
Very good little guide.

Just wondering though, does going through the in hose in the video pressurise the all the pipes, even the pipes under the inlet manifold or is it just the boost pipes

Nathan

I also have the same question.

Did the test today and found a leak at my BOV.
But I didn't get any pressure on the intake manifold!
So I could not check the hoses beneath the intake manifold.

I couls also hear some air flowing in the engine itself with the oil cap off.
But I think that is normal right?
 

Henk80

Guest
I did that already.
That is how I tested my IC system.
Could it be that the throttle valve makes such a tight seal that air can't get through it?

Edit: That isn't possible if I can hear the air passing the oil.
But I already found out what I dit wrong:)
 
Last edited by a moderator:

Henk80

Guest
I wanted to test the breather hose connected to the valve cover.
But with the oil cap off, you can't build up pressure in that hose.

So the hoses beneath the intake manifold did boosted up probably.
 

s1l3nc3r

ASBO car.
Jun 30, 2008
1,558
0
essex
Nice write up...Need to check mine for leaks as i think ive got one somwhere.

Not sure if ive got a air compressor could you not use somthing like a foot pump of somthing similar to build up the pressure in the system.?

Just to confirm you need to connect the tester up from the hot side before the intercooler.
 
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