Can anyone tell me how to modify a set of bosch 1600 to fit in my stock fuel rail??

 

Just have a local machine shop mill down the top end of your injectors. Give them a stock injector as a sample of the size (diameter) the plastic needs to be milled down to. You risk fuel leaks trying to modify it yourself using simple tools.

 

witchhunter.com will do it for $5 each IIRC.

 

You really don't risk fuel leakage because you have orings ontop of the plastic that needs to be milled down to stop any fuel from leaking. I did this myself to at least 2 sets using a dremel with a sand paper roll. Worked fine with no leakage

 

how much smaller did you have to go ??? is it significant do you risk the injector oring grooves not working as well?

 

I just kept test fitting them and as soon as they would fit in the rails, I stopped.