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Thank you all for your responses. We are first going to try swapping out the O-rings on the existing design with softer O-rings. If we were to go with the far right design concept, are there any concerns about not constraining the O-ring in an actual groove? Would the O-ring tend to expand...

Lucky Guesser, your name gives me a lot of confidence. I'm going to try a few with the right-side diagram, but also I'm going to try the current and new design with softer O-rings, and various thicknesses on the o-rings. I think we're well off the beaten path here, so I appreciate your...

Hello, long time listener first time caller. My foundry uses a water immersion tank to leak test brass valves that we cast and machine. Temporary plugs are installed into the valve and 20psi air is ported into the valve through a special plug. If air bubbles through the cast/machined surfaces...