jonny wrote:I had someone wanting me to post about the OPV I installed. I ended up using the Fluid-O-Tech unit since it was a direct replacement for the adapter that was already on the pump and it was a nice compact size (not a lot of space on these guys!). It was cheap at orphanespresso.com. I have the OPV mounted in such a way that it is easily adjusted by removing the case.
Thanks for the resource Jonny. I finally got a break from work and exploded and descaled my pump and reinstalled it with the OPV. Here's what it looks like:

Since I also insulated the boiler (thanks, RAS!), I didn't have clearance to route the return tube between the reservoir and the case. So I snuck the return line toward the Pstat and up the side of the reservoir to the inside of the machine. Since the hose was too short to drape over the side of the reservoir, I was thinking to myself, "Gee, it sure would be cool if I had something I could hook over the edge."
Then I realized that the cleaning kit I got from OE came with rinse bottles that will squirt around a corner. So I sacrificed the squirt tip on one of these bottles. It fit inside the silicon hose perfectly, and just hangs over the side of the reservoir:

Using a portafilter-mounted pressure gauge, I set the blind pressure (no water flow) of the OPV to ± 9.5 bar—per Jonny's recommendation—which should mean the operating group pressure is in the 8.5-9 bar range. The machine is definitely more user-friendly w/ the OPV in place. I hadn't pulled a shot in about a month, but immediately pulled two of my best shots to date after I put the machine back together.
Because the reservoir/pump mounting bracket is only attached to the main chasis via two hex head screws, this is an easy mod. Just unscrew the screws under the machine, lift out the mounting bracket, and go to town. You will need to pull the pump, but that's not a big deal. About $20 in parts from OE: OPV, 16" of hose (I ordered 12", but you might want a little extra length), and a few more bucks if you want to buy a sacrificial squirt bottle or some other clever reservoir return detail.
I'm also a big fan of the added boiler insulation. This does two things: improve the energy consumption, and reduce the amount that the water in the reservoir gets pre-heated due to proximity to the boiler. The latter should make temperature regulation at the group a bit easier, shorten my cooling flushes, and again improve energy consumption.
Installing the insulation meant pulling off the front plate of the machine. So I replaced the gaskets and seals at the group-to-boiler, HX-to-boiler, sight glass, etc. while I had everything apart. I'm just waiting to make sure that everything I serviced holds water—so far, so good—before I put a piece of boiler insulation on top of the boiler.
(The only bummer in all this was when I discovered that the FOT pump on my machine had been leaking—for years. The outlet cover was pretty rusty, especially on the inside. After the pump overhaul, it still leaks a little. So I'm getting a new pump from Doug and Barb and keeping the existing one for parts. If someone out there needs pump parts, just let me know.)