First unit broke when I tried to replace the impeller. HKS informed me incorrectly that the 7040 has a counterdclockwise thread. I uses an impact gun and broke the casing. Didn't recieve any discount when purchasing the new kit. Not even an apology.

I bought the new I ring, but haven't recieved the traction fluid yet. So tell me more about your idea...

 

Gasket maker. If this happened to me, I'd;
line both groves with gasket maker (permatex grey)
install the o-ring
install bolts and snug them (don't torque them down yet)
pull the thing apart and remove any excessive gasket maker that made it inside the case
put the thing back together and snug the bolts again
let the gasket maker set up for a bit (can't remember how long-read instructions) then torque the bolts

I'm really curious to know how the o-ring failed.

 

I have now idea how the o-ring failed. It just started leaking after I started the car. It looked like the o-ring had a flat spot. I got a new o-ring and I think that's a safer bet since it will take more heat and pressure than a Permatex gasket.
I will test the unit and pressurize it before installation. I'm still waiting for the HKS oil to arrive.

 

I’d use the o-ring too, but along with the gasket maker. That gasket maker is basically the same **** that’s holding our engines together so to speak. It’ll take the heat and will help form that seal should the crappy o-ring fail
you again. Either way, it’s good that the thing still works.

 

Sorry I know this is 2 years old but thought I'd ask anyway, at what RPM are you hitting boost on this pulley? And do you have any videos? Thanks!