Building a Valve Block Test Bench - some ideas
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Thread: Building a Valve Block Test Bench - some ideas

  1. #1
    LEGACY VENDOR 996TURBO's Avatar
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    Building a Valve Block Test Bench - some ideas

    Guys,

    I'd like to build a Test Bench for my Valve Block Rebuilds.

    Something looking like a Tanky

    I'd like to use OEM bits like tank and compressor that i have sitting in the garage.

    I started putting lines and bits of MARS kits in the ports in order to put pressure in there and see if the solenoids leaks.

    I'll source a EAS airtank for few bucks that i'll fill with a OEM compressor.

    Idea is putting all that stuff in a metal case and reduce weight and place.

    Next step is wiring a controller to control each solenoid.

    Do you have comments or ideas?

    Cheers

    Flo
    1997 P38 4.6
    LPG
    SD L322 Rack adapted to P38
    DC5000 EAS Compressor
    Arnott Gen3
    RR-EVOLUTION protection for P38 : front diff guard, rear diff guard, steering guard, fuel tank
    32 inch BF KM2 tires
    Custom Mantec Snorkel
    RPI Sport Exhaust
    H4 Bixenons bulbs

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  3. #2
    LIFETIME CONTRIBUTOR
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    Re: Building a Valve Block Test Bench - some ideas

    Flo, I wonder if you made something similar to a Rovair to control the solenoids (I have one).

    Also see viewtopic.php?f=3&t=22054 for a homebuilt controller info.

    My Rovair:

    Ron Beckett
    1995 Range Rover HSE 4.6 V8 auto
    2007 Yamaha XJR1300
    2006 Suzuki DL650 V-Strom

    RIP Bucko (1979-2008 - Riding on forever)
    http://p38arover.com/lee_pix/bike_caricature-avatar.jpg

  4. #3
    LEGACY VENDOR 996TURBO's Avatar
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    Re: Building a Valve Block Test Bench - some ideas

    That's on the TO DO List
    1997 P38 4.6
    LPG
    SD L322 Rack adapted to P38
    DC5000 EAS Compressor
    Arnott Gen3
    RR-EVOLUTION protection for P38 : front diff guard, rear diff guard, steering guard, fuel tank
    32 inch BF KM2 tires
    Custom Mantec Snorkel
    RPI Sport Exhaust
    H4 Bixenons bulbs

  5. #4
    FRESHMAN ROVER
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    January 31st, 2011
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    164

    Re: Building a Valve Block Test Bench - some ideas

    Are you building a test kit just to test for leaks or are you looking at a fully functional test?

  6. #5
    LEGACY VENDOR 996TURBO's Avatar
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    Re: Building a Valve Block Test Bench - some ideas

    Quote Originally Posted by zhoey
    Are you building a test kit just to test for leaks or are you looking at a fully functional test?
    I'd like to build a kit that test for leaks but also controls solenoids.
    1997 P38 4.6
    LPG
    SD L322 Rack adapted to P38
    DC5000 EAS Compressor
    Arnott Gen3
    RR-EVOLUTION protection for P38 : front diff guard, rear diff guard, steering guard, fuel tank
    32 inch BF KM2 tires
    Custom Mantec Snorkel
    RPI Sport Exhaust
    H4 Bixenons bulbs

  7. #6
    LEGACY VENDOR 996TURBO's Avatar
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    September 27th, 2006
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    Re: Building a Valve Block Test Bench - some ideas

    Got 2 EAS tanks his afternoon .

    One will serve as the EAS tank of the car that i'll fill with the compressor.

    The other will be filled by the first one using the valve block.

    Can't use bladders since there's no weight of the car.

    I got gauges, tees, 4 one ball valves.

    A 220-12V converter.

    Should work but i'll need help to operate solenoids directly from the drive box without any EAS Ecu.
    1997 P38 4.6
    LPG
    SD L322 Rack adapted to P38
    DC5000 EAS Compressor
    Arnott Gen3
    RR-EVOLUTION protection for P38 : front diff guard, rear diff guard, steering guard, fuel tank
    32 inch BF KM2 tires
    Custom Mantec Snorkel
    RPI Sport Exhaust
    H4 Bixenons bulbs

  8. #7
    JUNIOR ROVER
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    Chester, England
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    756

    Re: Building a Valve Block Test Bench - some ideas

    Hi Flo,

    I have built a test rig which also uses a Rovair control box.



    I bought part of a wiring harness from a breaker (38 GBP) which included the EAS ECU plug, the valvebox plug and the compressor plug. It plugs into Rovair unit and allows me to switch each individual solenoid.

    Each of the ports in the valvebox has a separate pressure gauge.
    It is very easy to see leaks with soap solution. I put the whole apparatus in a tray so I can spay it.
    Leaking solenoids and O rings are a doddle (what is French for doddle?).

    The test rig also uses a p38 air dryer and an accumulator tank.
    The whole setup is powered by a spare car battery and battery charger.
    The compressor is operated at the moment just by a crocodile clip on the battery. In the future I may fit a heavy duty solenoid switch so the Rovair compressor switch operates the compressor.

    I have rebuilt only 3 valveboxes and 4 compressors so far but god it saves time. It is much easier to test things out on the bench first.

    Dave
    2000 Range Rover 2.5 DSE HP24 auto - JFearn chip, larger intercooler, removable winch, stainless exhaust, Gen III's, GG AT2's. Faultmate MSV2.
    Land Rover folding mountain bike. Now with 1000W electric motor.
    ex-1996 Discovery 2.5 300Tdi diesel auto
    ex-1982 Classic 3.86 Perkins diesel manual

  9. #8
    LEGACY VENDOR Scotty's Avatar
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    Re: Building a Valve Block Test Bench - some ideas

    Does anyone no if these Rovair boxes are still available? I could really use one, I went to rover renovations but Dennis shows them out of stock.
    Scotty, head womble ~ "Make Good Use of Bad Rubbish."
    http://www.becmdoctor.com
    1996 Rangie; Upgraded lights/badges new Top Hat Motor
    1999 Rangie; Callaway Epson Green completey Rebuilt
    2002 Rangie; Black on Black Restored to Original Condition

  10. #9
    LIFETIME CONTRIBUTOR
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    Re: Building a Valve Block Test Bench - some ideas

    Try Lee at http://www.labtronx.com.au/ - he made them. I see he has a new website which isn't working that well at the moment
    Ron Beckett
    1995 Range Rover HSE 4.6 V8 auto
    2007 Yamaha XJR1300
    2006 Suzuki DL650 V-Strom

    RIP Bucko (1979-2008 - Riding on forever)
    http://p38arover.com/lee_pix/bike_caricature-avatar.jpg

  11. #10
    LEGACY VENDOR Scotty's Avatar
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    Re: Building a Valve Block Test Bench - some ideas

    Thanks Ron..
    Scotty, head womble ~ "Make Good Use of Bad Rubbish."
    http://www.becmdoctor.com
    1996 Rangie; Upgraded lights/badges new Top Hat Motor
    1999 Rangie; Callaway Epson Green completey Rebuilt
    2002 Rangie; Black on Black Restored to Original Condition

  12. #11
    Premium Member
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    Re: Building a Valve Block Test Bench - some ideas

    My mate had one up at Gaydon which he made himself. Built it up on a workshop trolley, and tests all compressors and valve blocks. From what I understand, the warranties sent back from Dealerships necessitated this so Hitachi could be given solid information a compressor had failed within warranty period. Unit had 2 tanks under it and a whole load of collet type connections mounted on the face of it with analogue pressure dials.

    Since the Tsunami in Japan, JLR have probably by now run out of compressors (I suspect they will be flagged as 'Backordered' if you check). Fortunately, I believe they have started to fit the 2012 compressors early on the assembly lines. These are much better units, but I think the problem JLR were having was the brackets to fix these compressors to the vehicles, which some F1 engineering unit were developing.

  13. #12
    FRESHMAN ROVER
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    Re: Building a Valve Block Test Bench - some ideas

    Quote Originally Posted by dave3d
    O rings are a doddle (what is French for doddle?).
    Dave
    Sweet setup there Dave!

    And French for doodle is "crème" (creamy). Yeah, you know how we are with pastries
    1994 4.6 HSE
    1972 109" SIII SW
    1967 88" SIIA

  14. #13
    JUNIOR ROVER
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    Re: Building a Valve Block Test Bench - some ideas

    BonJour Ben,

    doddle means easy peasy or child's play. doodle means sketch or drawing.

    Dave
    2000 Range Rover 2.5 DSE HP24 auto - JFearn chip, larger intercooler, removable winch, stainless exhaust, Gen III's, GG AT2's. Faultmate MSV2.
    Land Rover folding mountain bike. Now with 1000W electric motor.
    ex-1996 Discovery 2.5 300Tdi diesel auto
    ex-1982 Classic 3.86 Perkins diesel manual

  15. #14
    LEGACY VENDOR 996TURBO's Avatar
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    Re: Building a Valve Block Test Bench - some ideas

    Quote Originally Posted by dave3d
    Hi Flo,

    I have built a test rig which also uses a Rovair control box.



    I bought part of a wiring harness from a breaker (38 GBP) which included the EAS ECU plug, the valvebox plug and the compressor plug. It plugs into Rovair unit and allows me to switch each individual solenoid.

    Each of the ports in the valvebox has a separate pressure gauge.
    It is very easy to see leaks with soap solution. I put the whole apparatus in a tray so I can spay it.
    Leaking solenoids and O rings are a doddle (what is French for doddle?).

    The test rig also uses a p38 air dryer and an accumulator tank.
    The whole setup is powered by a spare car battery and battery charger.
    The compressor is operated at the moment just by a crocodile clip on the battery. In the future I may fit a heavy duty solenoid switch so the Rovair compressor switch operates the compressor.

    I have rebuilt only 3 valveboxes and 4 compressors so far but god it saves time. It is much easier to test things out on the bench first.

    Dave
    Dave,

    That is a neat setup there.

    I'll upgrade mine with your example ideas.

    This what i've done this week end. It worked well to show leaks at the solenoid valve stem on a rebuilt valve block.

    I don't even use a compressor, only a filled bottle at 9 bars. I don't use any air at all because i can cut air to the source with those one ball valves. Perfect.



    1997 P38 4.6
    LPG
    SD L322 Rack adapted to P38
    DC5000 EAS Compressor
    Arnott Gen3
    RR-EVOLUTION protection for P38 : front diff guard, rear diff guard, steering guard, fuel tank
    32 inch BF KM2 tires
    Custom Mantec Snorkel
    RPI Sport Exhaust
    H4 Bixenons bulbs

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