Building a Hydraulic Pump from Scratch - Tech

If you've ever wanted to take a hydraulic pump apart or put one together you should know that they are pretty much universal and most of the parts are interchangeable. In fact, the design of most hydraulic pumps has not changed since they were originally designed back in the day. The biggest change to the standard tail-gate pump has been that their makeup has gone from cast iron steel to machined aluminum.

Another major change has been to the pump heads, which are now Italian made and also constructed of aluminum. The Marzocchi pump head produces more pressure than the old Fenner Stone pump heads. These increased pressure allow the cars to move a lot faster and hop a lot higher. Of course, there are performance tricks that can be done to pumps, such as porting out the pressure lines, which allows the pressure to flow more freely through the pump.

In an overview, all standard hydraulic pumps are basically the same and their assembly can be applied to virtually any hydraulic pump. Now follow along as the Cool Car's crew in Kentucky assembles one of their off-the-shelf chrome competition pumps.

The CCE assembly line keeps busy as Raul builds pumps throughout the day.
This CCE Competition pump was ready to be assembled.
Alex started off by putting on the tank O-ring, which will keep the fluid from spilling out of the hydraulic tank.
Alex started off by putting on the tank O-ring, which will keep the fluid from spilling ou

The pump O-ring was placed on the block. This seal keeps the pump head from losing pressure between the block and the pump head.
The pump O-ring was placed on the block. This seal keeps the pump head from losing pressur
Alex removed two of the pump head bolts to allow the pump head to be tightened onto to the aluminum block.
Alex removed two of the pump head bolts to allow the pump head to be tightened onto to the
Here's a closer look at the O-ring that seals the block.

This plug keeps dirt from entering the pump head. This seal is important as it keeps the pump head working properly.
This plug keeps dirt from entering the pump head. This seal is important as it keeps the p
The Marzocchi pump head was ready to be bolted onto the block.
Alex torqued the pump head down to 20 lbs.

Alex used a little white grease to help the tank slip onto the block. It also works as a seal to prevent the tank from leaking.
Alex used a little white grease to help the tank slip onto the block. It also works as a s
Next was to slip the tank onto the block.
The new O-ring and backing plate keep the tank from leaking fluid.

Alex bolted down the backing plates.
Next on the agenda was to bolt on the chrome motor or armature and casing.
Before the armature and casing goes on you need to put on the key.

With the key on the block, the key splines was ready to have a motor bolted on.
Alex removed the bolts that kept the armature in place.
This electric motor received a bearing end cap which allows the armature to spin with less drag. This will lengthen the lifespan of the armature as it allows the armature to work cooler.
This electric motor received a bearing end cap which allows the armature to spin with less