Citroën ID/DS DIY sphere tester

This page describes how to make your own hydropneumatic sphere tester for the Citroën ID/DS models.

In order to test the suspension and 'high pressure regulator' spheres, a sphere tester is a handy piece of equipment. Described below is a tester you can make yourself. Bear in mind however that the construction has to be well made because during the testing of a sphere pressures up to 100 bars can be achieved.

This tester can be build with a simple hydraulic jack (a version up to 2000 kg) and the extender of the left hand suspension cylinder. Additionally you need a pressure gauge (0 to 100bars) and a connector for the gauge. All these components are relatively cheap to get and the tester can therefor be made for around $25.

Remove the jack piston if possible. This will make the testing easier. There is no risk when removed of damage to the sphere or shock absorber. When it is not possible to remove the jack piston it can be left in. Weld the extender on top of the jack. When you left the piston in the jack you should take care that the jack piston can still move upwards and downwards in the extender. Welding is best done using MIG to prevent heat distortion. Weld the pressure gauge connector to the extender as shown in the picture and drill a hole through the extender in the middle of the connector. This way the fluid pressure will be able to reach the gauge.

Testing with the piston removed out off the jack:

Drain the old hydraulic fluid out of the jack and flush the jack with the appropriate cleaning fluid. Afterward fill the jack with either LHM or LHS.
Place the sphere to be tested on top of the tester and test the sphere as described (Testing a sphere.).

Testing with the piston left in the jack:

Before each test push the jack piston completely downwards and fill the extender (on top of the piston) with hydraulic fluid.
NOTE: Be aware with this tester not to push the jack piston to far upward because it could easy damage the sphere shock absorber. During normal testing however this should not be a problem.
Place the sphere to be tested on top of the tester and test the sphere as described (Testing a sphere.).

NOTE: I can imagine that the jack seals are not resistant to either LHM or LHS fluids. I did build two testers (one for LHM and one for LHS) as described above and use it for over 5 years now with LHM without sealing problems. However this is no guarantee.