Injector Technology

Engineering that has gone into each injector:

Did you know that BDG has actually custom designed each part of these injectors to promote better life and longevity?

Take, for instance, the main control piston (spindle) of the injector. BDG has a proprietary DLC coating that we use on the commonly seized part—which is the main cause of the cold knocking, which creates a very hard wearing and almost frictionless surface.

Even the manufacturing process is quite involved: the material is sourced in Germany, machining is completed in France, and then it is back to Germany for heat treatment. Then it goes to Australia for QA checks, gets shipped to America for coating, and finally ends up in a laboratory in California for testing. Every single spindle follows this routine before it can be used in a Baileys Blueprinted Injector.

It’s a very similar scenario for the other major component within your injector, the nozzle. BDG specifies materials, tight and unique flow rates, reaction times, a similar DLC coating, and so on.

Baileys Blueprinted Injectors are built by our own team in our purpose-built $2.5 million facility near Wollongong, NSW. This facility is completely temperature controlled, dehumidified, and air-conditioned in order to promote the stability of metallic temperature required to work within a +/-0.001 mm window! Of the parts refurbished for re-use, refurbishment is completed in a manner that results in the end product being at least as good as the new part supplied in a new injector. Things like sealing surfaces are done to a much higher standard, as is the all-important injector body bore, with roundness measured down to 0.00004 mm accuracy (samples need to be sent to Japan for measuring down to this accuracy—it is not physically possible to have tolerances that small measured within Australia).

Lastly, the injectors are dynamically operated and run in a purpose-built test bench which in effect replicates the engine conditions and measures a number of key parameters. We have a two-stage testing process. First is a pass or fail validation to ensure that it meets our much tighter tolerances of fuel flow (for example, it’s possible to use the injector code to correct +/-8 mm3,  whereas our internal tolerances would be approximately +/2.0 mm3). Once we’re assured the injector meets BDG standards, then it goes into a coding bench.

By the time each injector leaves, it’s not uncommon that they have completed around 30–40 minutes of running or around 75,000-plus injection pulses. Given that this is a lengthy (but very important) process, BDG has invested into multiple test benches. It’s possible that 18 injectors are being tested simultaneously in our shop at any given hour!!!!

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