I've never heard of a single issue reported with a CPE pump on all the threads I've read. Even though the price is high, I think its worth it for peace of mind. It seems a lot of the internals installs (especially the new maxflo internals) are a crapshoot as to what fuel pressure you'll get. Some guys get less than stock or the same and others have good results.
Please do not post false claims.
1) what happened between your prototype kits and the production kits
which caused this kind of variation?
Nothing. There is no variation - its normal machining. The parts are
turned on a lathe, which holds a toleance tighter than .001". So, if
the machined diameter is .385" - pats will vary from .3850" to .3857"
- which is a huge difference.
Its just a matter of matching the right sleeve with the right piston
- too open and you get low pressure but it won't seize or gall at
all. too tight and galling and seizing starts up - but when the parts
work they truly perform. The medium, perfect fit has to be found.
2) how likely is it that we will be able to return these, measure and
swap, send them back out and expect success?
100%, no questions asked. there are no bad
machined parts at all - the machining is perfect, there is nothing
wrong.
3) how can this be prevented from happening again?
CDI is rematching everything in house - no questions asked - and further testing
a variance of different fits to know what performs and works, and
what doesnt. what seizes or galls up, and what doesnt. what
pressurizes adequately, and what doesn't.
4) what will the process be once pumps are back in your hands to
rematch (?proper term) the piston and sleeve?
every sleeve and piston are separated and start all over with the
matching process AFTER the different testing occurs. We'll get a
tighter fit with higher suction properties and run it and rag on it,
and log pressures, then something medium, and something loose.
loose is good - but loose can create ticking noise from the slappy
motion. its like trying to use an 82mm piston in a bore thats 84mm.