I want to thank all of you for the great information. I used to be a VERY regular poster on this site,..that is how I got my "inkjet Master" back in 2006. I jumped from this forum over to "Fixyourownprinter" because that site had 10 times more activity. It has kept me very busy for the last 5+ years. However,..there are very few people on that site that know anything about printers,... it is mostly for people looking for help. That is what I do. I forgot that I had to subscribe to this post to get any notification so I've been waiting a few days and got nothing. Now I know why.
Years ago I had some iP4200's and refill all the ink carts on them. At first I used 8mm stainless steel screws but immediatley the screw would hit or drag on the top cover. Not enough to stop the carriage or create an error but enough such that I worked on a different solution. I tried them all including hot glue (which was a mess) until I got flat head screws and even those were close. So I modified the top cover with a file and a hack saw to make sure there was plenty of room. After that I never had another problem with any of the 50+ printers that I have fixed and sold. This all changed once I got the MX860,... but since I own it and plan to keep it I have no problem getting out the hack saw.
Top Hat,.. thanks for the info about their inks. I can't believe there are people out there still passing off "Dye" ink for pigmented printers. They are part of the crowd that sell "Magic ink" --one ink for every brand of printers. What junk. I liked the CISinks web site for the DIY kit they sell and the tools in it. As far as the German method of refilling,... I have never liked it and I still don't. I have always felt that drilling a hole in the bottom rear would "Alter" the basic airflow design. The size of the air ven on the top and the balance of the two sponges, along with the exit port "Felt" are designed to supply the correct amount of airflow as each tiny bubblejet is expelled from a nozzle. The force of the bubble ejection creates a "Tiny" vacuum starting at the nozzle, through the ink well in the head, through the filter screen and back up into the ink cartridge. I feel adding a 2nd air path lower in the chamber completely changes where the ink is drawn from. Yes I know it works since 100's of people swear by it, but I would not use it unless I have no other choice. I also don't like that damage a needle does as it passes through the exit port "Felt". This has really got to change all of the "Vacumm" dynamics. Their answer is to use a "Blunt" needle,..since at least those are not sharp enough to cut the Felt in to pieces. The MX860 nozzle test print now show three test bands for each ink color,...5 pl, 3pl, and 1pl. Can any one imagine just now tiny the vacuum for is created by the ejection of a 1 picoliter ink jet bubble? Honey,...have you seen my hacksaw?????