Installing Big Brake Kit... Need Some Answers

[zeal86]

Ok... so I over torqued a banjo fitting on my BBK... The bolt, the line, and the threads on the caliper are fine but the crush washers are no good.

My install instructions are in Japanese and I can actually read most of the Hiragana and Katakana but not the Kanji. Anyway, Google translator generally does an OK job but not with these instructions... I've done this install one other time but it was 10 years ago.

So my questions are:

1) What is a safe value to torque a banjo fitting to on a aftermarket forged aluminum caliper? I've seen between 13 ft/lbs and 30 ft/lbs during my recent research. I'm thinking of going to 15 ft/lbs.

2) Where can I purchase crush washers with the following dimensions?: Outside diameter 14mm; Inside diameter 10mm; Thickness of 1.5mm; and 1.0 thread pitch.

3) Worst case scenario... could I reuse the OEM crush washers? They almost match the dimensions of the crush washers that came with my kit except for the outside diameter which is 16.16mm.

OEM crush washer on the right



Thanks in advance.



projekt zeal86 build

[mrk1]

Bring the banjo to a local parts store, my local napa has a bin of assorted crush washers.

[Ornelas66]

I had a similar problem with Hayabusa brakes and an old mechanic told me to scorch the old cooper crush washers with a lighter. I don't know why, but it worked. Good luck buddy, hope this helps

[zeal86]

Originally Posted by mrk1

Bring the banjo to a local parts store, my local napa has a bin of assorted crush washers.

I tried Napa, O'Reilly's, Autozone, Midas, and a Nut and Bolt business. Napa did not have any on hand but they could order something close but not metric...O'Reilly's had a 10mm 1.0tp but the outside diameter was a whole lot bigger than 14mm...Midas was clueless, and the Nut and Bolt business did not have any crush washers.

Pretty much close or out of luck locally...

I was hoping someone on this forum could point me to a website that would carry the crush washers I need.

projekt zeal86 build

[zeal86]

Originally Posted by Ornelas66

I had a similar problem with Hayabusa brakes and an old mechanic told me to scorch the old cooper crush washers with a lighter. I don't know why, but it worked. Good luck buddy, hope this helps

Thanks for the heads up on that trick, I'll have to look into that... I'm guessing the heat causes the copper to expand... possibly regaining (or close to) it's original shape.

projekt zeal86 build

[zeal86]

Any one know of a website I could source metric crush washers from?

[LucidMomentum]

Originally Posted by zeal86

Any one know of a website I could source metric crush washers from?

McMaster Carr?

[zeal86]

Originally Posted by LucidMomentum

McMaster Carr?

Tried that one... actually just minutes ago... all their 10mm copper washers were 20mm wide.

Thanks for trying to help...I appreciate it!

projekt zeal86 build

[Ultramaroon]

Originally Posted by zeal86

Thanks for the heads up on that trick, I'll have to look into that... I'm guessing the heat causes the copper to expand... possibly regaining (or close to) it's original shape.

projekt zeal86 build

Crushing the washer work-hardens it. Heating and slowly cooling anneals it. Use the factory specified torque value. It's standard hardware. I'll find the table and post it.

[Ultramaroon]

[zeal86]

Originally Posted by Ultramaroon

Crushing the washer work-hardens it. Heating and slowly cooling anneals it. Use the factory specified torque value. It's standard hardware. I'll find the table and post it.

Thanks... once again we are thinking the same... lol I was watching this [ame=http://m.youtube.com/watch?v=RMLqlDSsQpA] Annealing Copper [/ame] right before I read your last response.

projekt zeal86 build

[Ultramaroon]

Originally Posted by zeal86

Thanks... once again we are thinking the same... lol I was watching this

right before I read your last response.

projekt zeal86 build

Nice!

[zeal86]

@Ultramaroon I think I might try 15 ft/lbs but I still want to wait on some more input.

I really don't want brake fluid running down my calipers on to my wheels. That would suck! Gotta get it right this time.


projekt zeal86 build

[zeal86]

So what torque values do Essex, StopTech, Wilwood, Project Mu, AP Racing, etc... instructions suggest or state for the proper torque at the banjo fitting?

My Runduce calipers are made of forged aluminum. Not sure what metal the banjo bolt consist of but it is a 10mm x 1.0tp.

I've seen between 13 ft/lbs and 30 ft/lbs during my recent searches. I'm thinking of going to 15 ft/lbs but before I do I would like some more input.

Thanks in advance!



projekt zeal86 build