Merlin Front block will not seal up

[Greaterthenjake]

So for whatever reason I cannot get this thing to seal. It leaks between the body and the frontblock. Is the counterbore supposed to be larger than the Oring diameter on these? Its like the oring is pushing out into the counterbore and leaking between the two. When I disassemble the oring is no longer in the groove in the banjo bolt.

Small update: After messing with it a bit it sealed up for a bit and then started leaking again... The leak is smaller now but still excessive.

Is there a trick to this?

[Hellion360]

You got pics of the block?

Some of my merlins have three rings, some have two. The ring between the body and frontblock can be seated by screwing it in while under gentle regulated pressure. The o-ring should not be smaller than the counterbore.

[Greaterthenjake]

My merlin is a two oring deal. I will get the frontblock off hopefully later this evening. How are you going about gentle regulated pressure when screwing in the frontblock. Also I have a brand new sidewinder on this with the adjustment screw flush. Should I drop pressure and air it up slowly to seat the oring? I have shredded a few orings from them popping out of the face groove on the banjo bolt. So I will need replacements do you use urethane?

[Frmrspec]

Have you tried a fatter oring? Like a 115? Or 16x2mm?

[Greaterthenjake]

I have not tried oversized orings. This is my first merlin build and I needed a new banjo so I went with what I got initially.

[Greaterthenjake]

I took it apart this evening. I am attaching pictures of the frontblock you can see in one angle where the oring has pushed out of the face groove on the banjo, and the counterbore where you can see the oring is smaller when the banjo is in the body. I am terribad with a camera forgive the images.

[Greaterthenjake]

I may have solved this if anyone has this issue in the future. I added a third oring on the threaded portion of the banjo before installing the front block for a total of three orings. It now seals up and no bubbles with soapy water.