Peter,
I once had a brand new AC pump and found that the diaphragm was cut at one of the screw holes. (the small screws that go round the outside -about 6 of them.(Lotus elan)
I have also built the Bristol 400 pump I have on my car and the diaphragm rod is hard to relocate in the actuiating lever (like geoff describes).
You say one key thing for me--the manual primer works,suggesting poor mechanical engagement somewhere---note the pump when fitted rides on top of the camshaft. On the lotus you could put it on underneath if you were not careful and get no pressure--I recall this when fittinmg to my 400 as well. I would turn the engine over on the start handle so the cam lobe is at a low point.
I am assuming your diaphragm rubber is nice and shiny and not destroyed to just cloth by methanol in the fuel.
I also test the pump on the bench before fitting to ensure flow direction is ok & all works.
If you are fitting a electric pump a lot of people use Facet red or silvertops with a filter king filter & pressure regulator.
(made by Purolator Products Company, Elmira, New York. The UK agent/distributor can be contacted on 01784 493555 )
I would fit it out of sight at the rear of the car underneath.
Be careful with polarity of your car & the pump (ie positive or negative earth) and you will need to make a small blank plate for the mechanical pump or just disable it and allow the electric pump to push fuel through it for a period look.
Graham
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