Pictures of Honed, EDM'd and Drilled Nozzles (Click on pictures to enlarge)

This picture represents a Bosch nozzle after EDM (Electro Discharge Machine) followed by AFM  (Abrasive Flow Machine).  Notice the slightly rough transition area and the accurate hole size.  (the holes in this nozzle are angled becuse the injector sits at an angle in the cylinder head.  There is also an illusion of different sized holes becuase of their distance form the boroscope). This is the same nozzle as above after the Hone process.  Notice the smooth edges that help fuel flow and promote atomization while keeping the holes size and spay angle the same. This is a Honed 7.3 Liter Powerstroke nozzle.  Notice the rounded edges, cosistent hole size and seperation. This nozzle is and aftermarket EDM (Electro Discharge Machine) nozzle.  Notice the inconsistent hole size and separation between each hole. This picture has a reference # to show how far each hole is separated.  We admit this is a crude example but it helps show how far off the separation between each hole is.  This inconsistency will effect spray angle. This is an aftermarket EDM nozzle that was damaged by the EDM wire being inserted too far into the injector nozzle.  Notice how rough each hole is where the fuel flows out. This is an aftermarket drilled nozzle.  Each hole has been enlarged by a carbide drill bit.  Notice the obvious change in spray angle.