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Originally posted by Since87
Only 21 pages to wade through to find it. 
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and for the benefit of the "search handicapped", here's Bill's advice:
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after designing and doing failure analysis of o-ring joints for many years (in both static and cyclic pressure service),
there are several useful guidlines:
- when the component surfaces make contact, as they must, there should be 30 to 40% compression of the crossection
- the o-ring's volume should be between 60 and 70% of the groove's
- using a 30 to 50 Shore A durometer (hardness) material will make the surface finish less critical
- the o-ring's (centerline) length should match the groove's (do NOT stretch)
- the groove must have an outer containment ring to 'capture' the o-ring, else it is functioning as a gasket (different design basis)
do not use a sealant with the o-ring (no need if properly designed, will overfill the groove, make disassembly a pain, etc)
o-rings, properly designed, are FAR more reliable than gaskets
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