The New Hotness

The battered Champion hose nozzle came into play last fall, leaked profusely when turned off, went to a Safe Place for the winter, and recently emerged:

The conical surface (to the right of the tip) must make perfect contact with the edge of a perfect cylindrical hole in the outer shell to shut off the water, which was obviously no longer happening.

There is no reason why that hole should still be concentric with the outside of the shell, but centering the latter in the four-jaw chuck put the hole within about 0.2 mm of where it should be:

I defined that to be Close Enough™ and made the hole smooth & concentric with a teeny boring bar and sissy cuts. A drill would likely have worked well enough, too.

Gently filing the nastiness off the cone showed it wouldn’t suffice, so center it while noting the irregular diameter all around:

A skim cut revealed the need for more attention:

Another tenth of a millimeter improved its disposition:

Gentle touchup with a fine file reserved for special occasions may have been a further improvement:

Add a dollop of silicone grease to encourage the shell to turn much more easily on the O-ring, reassemble in reverse order, and top it off with a new hose washer.

A quick test on a reasonably warm day showed the cone met the cylinder poorly enough to consign this nozzle to the brass recycling box.

It was fun trying, though …