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Message: [QUOTE="Cold Roller, post: 636576, member: 9551"] Surface area is Pi r^2 D=6.347mm r=3.174 A=3.1416*(3.174^2) = 31.64mm^2 70mm^3/31.64mm^2= 2.21mm (0.0870") Your math is correct, but you don't want to take 2.21mm off the intensifier piston. The regular injector volume wastes some fuel that is held above the spill port. I would suggest that you need 6.5mm of barrel length, maybe a bit more at rest. 6.5mm of barrel gives a chamber volume of 205.7mi^3. So you would only need about 1.55mm (0.061") off the intensifier piston. This is why you need to measure twice and cut once. The plunger would be cut less than this to use excess barrel. A rough number would be 0.89mm (0.035") off. Whether I am 100% correct is unknown since I did not flow my injectors, but volume below the spill port is certain and volume above the spill port is only partially available for the stroke. Who knows, maybe someone with the tested data will offer a sizing for the cut. [/QUOTE]

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