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Continuing from the success of the 24 Valve VP44 Mach series injectors, the FLUX series injector nozzles for the Common Rail build on that history even further. Powering everything from mild to crazy wild engines. They are not just a common commodity extrude honed nozzle that so many market. The Flux nozzles are a highly modified piece that employ everything from micron accurate EDM machining for increasing the spray hole size to final finish honing for perfect flow rate matching between all nozzles. Flux nozzles are flow tested and matched using ISO 4113 test fluid. ISO 4113 is safety fluid with much higher consistancy in viscosity and density than Diesel fuel. We flow our nozzles at high pressure with this ISO test fluid at ranges from 100 to 1200 bar ( over 17,000 psi ) and measure the flow with an industry unique gauging system. This allows a matching closer than a stock part from any OEM manufacturer and multiples higher than many aftermarket vendors who use shop air at 50 psi. Shop air at 50 psi actually produces a part with looser flow matching than a mass produced OEM nozzle from Bosch, Delphi, etc.

Flux Mileage Max 20 HP    $1100.00    20 HP gain over a stock nozzle. The 03-04 Flux is a brand new custom piece that is sized smaller than a stock OEM nozzle. This decrease in size still adds 20 HP through tighter, less leaky tolerances, lighter internal pintles that waste less energy, and the smoothest internal surfaces compared to any nozzle made.

For the 04.5 through 07 engines we use the factory nozzle but employ changes to the internal geometry, internal grinding and again perfect flow balance. This nozzle has a slightly higher than stock flow rate.

Flux 1 40 HP    $1100.00    The Flux 1 is produced with a mild performance upgrade in mind and in nearly all cases an increase in fuel economy is expected. Nozzle specifications are shared with the Mileage Max nozzles above, but this nozzle has a higher than stock OEM flow rate for both engine types.

Flux 2   100 HP   $1100.00     100-105 HP over stock. Intended for large single turbos and compound turbos. The 03-04 engine uses a new custom nozzle with modified spray hole count and geometry. The 04.5 - 07 engines will use a factory stock nozzle with heavy internal modifications like EDM machining and final finish honing.

Flux 3 and 4 Hellfire 150-200 HP      $1200.00    150 to 200 HP gains. The Flux 3 and 4 were the first to break through the 700 and 800 HP barriers respectively.   All Flux Hellfires use a custom nozzle like their little brothers above, but have a large flow rate and discharge coefficients higher than any part on the market. The injection rate is lightining fast and cylinder pressures can exceed the limits of the stock head gaskets. Studs are a beneift, but failures of the stock gasket could still be experienced with a Flux 4.

Why a Flux Nozzle? The Flux series injectors are designed to give outstanding durability in hostile conditions. They utilize a steel alloy made to withstand very high accumulator pressures and high temperature. Flux injectors have been tested to over 39,000 PSI in sled pulling and drag racing trucks with zero crack failures for an 18 month period.

For the 03-04 ( not the 600 and 610 engine )the Flux spraying holes are formed on a new, blank nozzle with the most accurate microscope directed EDM machining available. All parameters of fuel flow rate, parallelism, spray angle agreement and spray hole size are exact. Our fuel flow rates are the most accurate to real world conditions than any. This gives smooth idle, even power to each cylinder and and even piston crown temperatures. The 03-04 Flux nozzles are not a "stock" or OEM part from Bosch, Lucas, etc. They are custom built for us by world class manufacturing facilities with 100% of the finish labor and final testing done in-house. None of our parts are sourced from third world countries.

The 04.5 through 07 model year engine Flux injector will use either a custom nozzle as the Flux the 03-04 engines above or a Stock Bosch nozzle that is heavily modifed with internal and external grinding, EDM machining and mild honing to clean up and smooth the spray holes.

Our long term testing of the Flux nozzle since April of 2004 has allowed us to tweak and change parameters to make a final product that is quite literally far superior to any performance injector on the market. This is part of the reason F1 Diesel has and continues to have the highest resale value, highest long term durability and some of the highest powered engines in the country.

Flux 5      $ 1200.00      The 5 produced 1289 HP in an engine using Nitrous injection. This nozzle is a unique piece in that it remains very driveable in the 03-04 two injection event engines producing low levels of soot and smoke for its size. No nozzle even comes close in terms of performance when measured against smoke and tailpipe soot output. Custom sized spray holes are formed on a highly efficient nozzle platform that then undergo a final honing phase that is second to none.

Flux 6    $1200.00      When used with large compound turbos this injector has produced over 1090 HP using Diesel fuel only. Tim Barber of TRE Diesel has partnered with the Smarty ( MADS electronics ) for tuning, MPI's Nathan Wright for compound turbos and F1 Diesel for injector and camshaft technology to bring together a combination of power and durability.

Flux 7?    $1300.00      Really, a Flux 7 exists? The answer is yes and no. The rumor is: Erick Brown of Browns Diesel made over 1100 HP using Diesel Fuel only with a Flux 7.   So far only a handful of people even have the air flow to support this monster so we just dont have the mounds of data to "claim" like we do with our other nozzles.   In the coming weeks of the New year 2009 we will see just how much power this injector can produce or how many rods we can send through the oil pan. ( -:

Custom Flux Sizes    $1100-1300.00    We can build a custom size for your application. Given the diversity of the turbo systems and engine combinations out there now, we can make up a special size nozzle just for you. Tell one of our dealers your combination and goals and they can give advice on sizing based on their experience.

What we do when we upgrade your injectors:

Step 1: Cleaning and Flusing:   Complete flushing of the injector using a catalyzed cleaner and heating is first in step 1. We run the injector on our Common Rail cleaning bench with a high strength catalyzed cleaner while heating at the same time. This activates the cleaner to break up carbon, gums and varnish that form inside the injector over time. Freeing up all the internal parts to operate properly for an accurate function test that follows. This is a 30 minute process to allow the element to heat the fixture to operating temperature and fire the injectors over 7000 times each at a pressure range of 5000 to 20,000 PSI.

Step 2: Solenoid Check:   Complete function test of the electrical solenoid. Voltage testing, resistance testing and coil inductance testing are all performed and logged.

Step 3: Volume Testing:   Flushing of cleaning chemical with clean and micro filtered ISO 4113 test fluid is first in this step. After flushing, the injector is flow tested by firing the injector solenoid with the proper voltage and current. This allows us to measure the output of the injector. Factory specified numbers are compared to make sure the injector is operating as designed and is delivering the correct volume of test fluid. Typically the test sequence is run for 20 minutes per injector and fires the injector thousands of times. The test sequences are designed to simulate all solenoid "on-times". If all tests pass the bench routine they are forwarded from the test area to the nozzle changing area. Currently we are the only performance injector company with the tooling, parts and equipment needed to make a proper repair of Common Rail injectors. Faster and more efficient equipment is continually being added to our shop to support this service.

Step 4: Assembly:   Injector fixturing, nozzle removal and remounting. While a simple process most would be surprised to know there is a proper method to remove and re-install a CR nozzle on its host body/holder. This requires a fixture designed to hold positive pressure on the nozzle tip while the retaining but is removed. This prevents the nozzle alignment pins from breaking and while re-installing the new nozzle allows all the retaining nut force to be used to apply torque and not allow the nozzle to twist.

Step 5: Final Volume Test and Balancing: Retesting with the new nozzles is next. Complete function testing and the volume of injection quantity is measured with the newly installed nozzles. In addition we also perform a nozzle opening pressure test. This is very important and not done with a common commodity nozzle swap in Do It Yourself nozzle kits. Slight variations in manufacturing can change the force required to open the nozzle with pressurized fuel.   Nozzle opening pressure should be checked and adjusted with the proper shims on all injector nozzle swaps. All injectors are assembled, final tested, and packaged in a 20 x 28 HEPA filtered, class 100,000 clean room. This is to insure no contamination.

All test data is logged and entered to each injectors serial number before shipping.