Attempt to rebuild Boge leveller.

From memory (and I've only done one, and that was as a spare pair of hands)

you have to have the total oil volume correct first, have a little oil in all areas, add the rest to the top half which is the reservoir prime it buy actuating it its full length a few times slowly, compress it to its shorest length, doing the nitrogen purge thing at low pressure, sealing the top section up with a piffling of pressure in it and then raising the pressure in only the HP section to the spec pressure (which I dont remember).

Fantastic!!! Can you remember if the top section has the same nitrogen pressure added as the lower (I can only find one reference that says the high pressure accumulator is 20-30 bar). I can gas both to these, but I figure that will be to much for the oil reseviour bladder :confused:

As you have suggested, the oil reseviour will be empty. I filled the lower area behind the high pressure accumulator with oil. Re-assembled and pumped it up and down. I figure I'll need to pressure the high pressure accumulator to force any oil back up into the oil reseviour still. I can't "see" the oil level within it... so it's all guesswork. :)

Quote:

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Originally Posted by DoubleChevron

Fantastic!!! Can you remember if the top section has the same nitrogen pressure added as the lower (I can only find one reference that says the high pressure accumulator is 20-30 bar). I can gas both to these, but I figure that will be to much for the oil reseviour bladder :confused:

As you have suggested, the oil reseviour will be empty. I filled the lower area behind the high pressure accumulator with oil. Re-assembled and pumped it up and down. I figure I'll need to pressure the high pressure accumulator to force any oil back up into the oil reseviour still. I can't "see" the oil level within it... so it's all guesswork. :)

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without the manual, from memory and some guess work id be doing something like this.

fill and purge the pump assembly
half fill the HP chamber with oil
1/3rd fill the reservior with oil
purge both chambers with nitrogen (fill to say 10 PSI vent and repeat)
precharge both sections to very low pressure (1-2psi)
action the boge from fully open to fully closed 3-5 times in its normal orientation do not lay it over or tilt it out side of its normal operating positions after this step
compress the boge and install with the suspension at full droop
add 10psi or so to the lp chamber
add 20-50 psi to the hp chamber
lower the vehicle onto the suspension and allow it to compress
slowly raise the pressure in the HP section to the minimum operating pressure)
bounce the vehicle to actuate the boge and level the vehicle
raise the pressure to nominal value
add load to the vehicle (take it to max nominal rear axle weight)
raise the pressure to compensate for the load (do not bounce, the nominal oil level has been set)

Wow thanks.... Yes I can't follow that as it'll have to be out of the car to add the nitrogen. I'll just have to make do and guess at the maximum pressure. If they should be between 20 and 30bar. I'll add 25. I will add and vent a few bar as suggested and work it to get the oil through the pump.

I wonder how the guys rebuilding them do all of this without fitting them to cars.

seeya,
Shane L.

Would they have a jig that holds them upright and is able to actuate them to do this?

Quote:

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Originally Posted by Homestar

Would they have a jig that holds them upright and is able to actuate them to do this?

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I might be able to stand it up in the press and cycle it through a few actions. I'll try. I need to pull it back apart first and bleed/fill the pump as described.

Ok, how I'm doing this (lets hope it's worked).

http://www.aulro.com/afvb/attachment...0&d=1459575915

I built this a few years ago... It's really dodgy, I don't know how to use a lathe so obviously make "not good" stuff when I tinker :wasntme:

http://www.aulro.com/afvb/attachment...1&d=1459575915

http://www.aulro.com/afvb/attachment...2&d=1459575915

This jig was made to add upto 75 of nitrogen into the top of citroen spheres. He's an example of one of the variety of spheres. As you can see you clamp the head onto the sphere and add nitrogen. But how do you unscrew the filler plug and screw it back up with over 1000psi of pressure in there ?

http://www.aulro.com/afvb/attachment...3&d=1459575915

and little blob of junk with now half stripped out grub screw that grab the filler plug (they don't need to be tigthen a lot by the attatchment .. only touch the 'O'ring under the plug down).

http://www.aulro.com/afvb/attachment...4&d=1459575915

I wanted to figure a way of using this to recharge the boge leveller.

http://www.aulro.com/afvb/attachment...1&d=1459576416

I chopped the top off of a suspension cylinder I laying around with a hacksaw...

http://www.aulro.com/afvb/attachment...1&d=1459576416

The recessed bit where the citroen sphere screws down locks perfectly over the 'O'ring in the sphere regasser ... So I mangled it good with a round file trying to match up the cylinder shape of the boge leveller. I also tried to cut a ridge in there with a dremel tool to contain the 'O'ring.

http://www.aulro.com/afvb/attachment...1&d=1459576416

That big square section 'O'ring is a later sphere seal.

http://www.aulro.com/afvb/attachment...1&d=1459576416

It took a few attempts, but if I'm really careful, amazingly I can get 25bar in there without the 'O'rings blowing out.


http://www.aulro.com/afvb/attachment...1&d=1459576416

So now I need to loosen and tighten the filler screw

http://www.aulro.com/afvb/attachment...1&d=1459576895

http://www.aulro.com/afvb/attachment...1&d=1459576895

http://www.aulro.com/afvb/attachment...1&d=1459576895

Man I'm amaze even me with how ****ty I can make stuff and still get it to work :D

Anyway, I went through as much as the process as I coudl that's described above. I bleed and filled the pump, assembled and lightly pressurised it and pumped it through it's entire cycle (you can easily do this by hand with only a few psi in the bladders).

http://www.aulro.com/afvb/attachment...1&d=1459576895

It kept leaking around the thread at the end. I assumed it was like a tire bead and needed pressure behind it to seat (only I couldn't get it seated). You actually need to drag the lip on the edge of the rubber bladder up and over the edge and insert the end cap into as shown.

http://www.aulro.com/afvb/attachment...1&d=1459577236

I gassed top and bottom to 25bar....

http://www.aulro.com/afvb/attachment...1&d=1459577236

I'll just have to fit it up and see if it works.

I can't help but wonder if the rebuilders just spray it with a coat of paint and regass it. The oil inside looked really good, you would only change the 'O'rings in the end plate if it was leaking (there is 3 there ...so all three would have to be damaged for it to leak). There's nothing inside that can be rebuilt, especially as I doubt you can buy the nitrogen bladders.

seeya,
shane L.