2 days of fairly dedicated trouble shooting have uncovered many things.
First, My air leak was caused by several small holes cut into my small vacuum line that runs to my in-car gauge. Some of the hoses slack must have gotten caught up near/in the hood hinge and it pinched it so much it cut up a large section of the hose badly. I have spliced in a new section of hose and hope my fairly hasty fix will hold up.
Second, Temperatures in excess of 180F warp/melt the small sacrificial filter. You know the clear one just before the injection pump. It usually only costs a few dollars at the auto-parts store. Ideally in a good system this filter is almost not needed as nothing harmful should make it that far down the chain. However I have noticed that on several occasions I have found black/slimy/flaky gunk starting to build up in the filter. After some experimentation I discovered that this was coming from the diesel side of the system, SCARY… the only thing I can think of is that the WVO contamination that happens over time with a 1 switch system like mine is clearing out more junk in the diesel loop? So I have found a solution. I found a re-usable filter housing with re-usable filters at a auto parts store here in Oregon. It wasn’t cheap ($10.00) but I suspect it will save its cost in the next 6 months. I boiled all the plastic components for 10 minutes in a rolling boil (212+ degrees?) and the parts did not even soften so I suspect they will hold up to my WVO temps. I will post pictures as soon as I can.
Third, That diesel is thick when its been contaminated to 50% or more with WVO at 40F. After a severe hot snap of I think a almost record breaking 97F a few days ago last night it got down to 40 degrees here in downtown Bend. I had only put 5 gallons of #2 Diesel in my tank roughly 5 weeks ago and driven 4,000+ miles. The gauge was nearing empty but not totally. Looking at the thickness of what I was pumping out of the diesel side I would say it was 50% or so WVO. I am curious as to the possible harmful side effects to running so much WVO in the un-heated side of my fuel system. When I am doing heavy town drivng I suspect half of my driving time is on Diesel not WVO. Am I coking things up? and if so how can I reverse the effects.
Fourth, As soon as possible, buy the largest bag of GOOD hose clamps I can find. The cheap ones you get everywhere are just junk. I have, maybe upwards of 50 of them in my system if you tighten them to much they can actually cause air leaks themselves not to mention they cut-damage the hoses. Several different types of clamps exist. I need to do more research.
Fifth, It is lonely traveling, alone. I need some companionship in a dire way. Having many lovers scattered about the continent is great when I can expect to see them soon, But when I am not sure where I will be and for how long the distance starts to hurt.