Jim Wilkins wrote:

Suggesting solutions would be easier if we knew what machine tools you
have available.


The tool kit is fairly modest: 10" lathe, hand tools, files, drill and
wrenches. Arc welder also, but it's more of a menace in my hands....

One addition to the kit is a leak test fixtu A fitting that allows
me to connect the fluid fill hole to a bicycle pump and pressurize
the reservoir with air. I _should_ have done that test first.

This whole goose chase started when it looked like the two "outer tubes"
in the parts diagram were leaking where they joined the "unit body". The
air presure leak test suggests the leak is _not_ at the tube-to-body
joints, but rather at the safety valve seal, item 14. If that's true,
there's no need to completely dismantle the assembly; the pump and lift
cylinder packings and safety valve port seal can be replaced without
touching the two stuck fasteners. A spanner to tighten the pump packing
with the piston installed is still necesssary, but not too hard to make..

At this stage it's probably wise to repeat the air pressure leak check
a couple of times with soapy water as a tracer. The jack ought to
have a vent somewhere in the system, which I haven't found.

bob prohaska