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The drill bit pictured in post #1688, is it the size of the O-ring? Was there any mod done to the drill bit before using it?
To render a non-interference fit to the raw castings .062" bore -- created by the brass rod core during the casting operation -- it is hand reamed with a standard (non-modified) .065" bit.
The two encapsulated O-rings, within the seal body, have a nominal .060" inside diameter, but those surfaces (being much more elastic than the surrounding resin) scoot out of the way when reaming with the over-size bit. This leaves the resin bore enlarged enough to easily pass the pushrod, with the O-rings projecting into the bore enough to girdle and make watertight the fit between pushrod and seal body.
Sorry, not sure of what I am looking at in the last five pictures. Multiple pushrod seals? But looks like a lot on one shaft for multiple casting????
Yes. And yes.
It's easier to use one long brass rod core than a bunch of short cores. The current tool has three ten-seal castings, and two eight-seal castings. After casting each core rod is pulled and the individual pushrod seals separated on the bandsaw.
Here's the less efficient 'old-school' pushrod seal tool and casting -- too labor intensive.
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