Hi
Is it worth just going to a local Diesel Injector repair shop? there are loads around in most areas. Either ask them to do it or see if they have a crush washer?
Have you tried annealing either the copper washer or the aluminium one. Most washers should be annealed before using.
It won't fix any damage to the washer but it will soften it to allow it to deform and seal better.
https://makeitfrommetal.com/how-to-a...ginners-guide/
Quote:
For Aluminium
How to Get Annealing Right Every Time by Hand
Might as well start with what you’re probably the most interested in.
If you already know that the grade you’re working with can be annealed, and it’s worth doing, here’s how you can nail the annealing (almost) every time:
Get a Sharpie.
Yeah, that stupidly cheap little permanent marker. You’ve probably got 3 in your toolbox right now. It doesn’t matter which kind. It doesn’t even really need to be Sharpie brand (although I don’t know why you wouldn’t want to use them).
Scribble all over the piece of aluminum. Don’t worry about covering it 100%, just enough to leave a mark on every general area.
Now get out your torch. Start heating up the part. Don’t heat it up to fast, and keep the flame moving over the whole part to keep the heat even. You don’t want hot spots. It’s actually really easy to overheat and melt the material (annealing happens at a temp just a hair under the melting point), so be patient and take your time.
You’ll see the sharpie marks changing color. Then, at a certain temperature, they’ll pretty well disappear. That’s the sweet spot that you’re looking for. Quench the aluminum in water and you’re done!
The cool thing about this method is that it gives you a lot of options for heating up the aluminum, based on what you have. You can use an oxyacetylene torch, a propane torch, whatever’s on hand that can get the material up to around 775 F. This is the ultimate DIY way of annealing aluminum.
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Iain