Copper Gaskets for Banjo Fittings on Brake Lines

[46th Georgia]

The stock copper banjo fitting gaskets are about 1.5 mm thick and the only ones I can find locally are 1.0 mm thick. Would they work O.K.?

 

[spresser]

Yep they will work. It's what I've used on mine. Might be a good idea to sand down any inconsistencies on the caliper end though. I needed to, there was a bunch of buildup there.

 

[Jim]

I'd use it. I'd anneal it first though.

 

[bosco659]

I’m a firm believer in annealing copper washers before use, even new ones. If you need to be convinced, get two new washers from the same source. Anneal one and then try to bend each one using your fingers only. It’s surprising how soft the copper becomes after putting heat to them.

This winter I rebuilt the front brakes, replaced lines and had several leaks I had trouble stopping using copper washers. I ended up using Dowty washers (steel with a rubber seal) and that did the trick.

 

[OHRider]

I have been using aluminum washers

 

[46th Georgia]

Thanks guys. Will use the thinner washers after annealing.

 

[bosco659]

I have been using aluminum washers

My new Russell fittings came with aluminum washers and I bought a spare pack from them that were aluminum as well. I wondered if they sealed better or it was a cost saving measure? Aluminum work ok but are more difficult to anneal. @Jim explained the process in another thread. If I find it I’ll post it.

 

[jetmechmarty]

My XS1100 has aluminum sealing washers all over the place from the factory. OEM replacements are aluminum. I use copper as economical replacements.

 

[OHRider]

My new Russell fittings came with aluminum washers and I bought a spare pack from them that were aluminum as well. I wondered if they sealed better or it was a cost saving measure? Aluminum work ok but are more difficult to anneal. @Jim explained the process in another thread. If I find it I’ll post it.

I only use the aluminum washers one time. Never tried to anneal an aluminum washer. My BMWs used aluminum washers for all the plugs on bike. Spiegler lines use aluminum washers.

 

[jetmechmarty]

I only use the aluminum washers one time. Never tried to anneal an aluminum washer. My BMWs used aluminum washers for all the plugs on bike. Spiegler lines use aluminum washers.

I saw a short video on annealing aluminum that I think fit this purpose. The aluminum was marked with a Sharpie. It was then heated with a torch to the point that the ink disappeared. The demonstrator cooled it slowly, then demonstrated how soft it was.

 

[Jim]

I saw a short video on annealing aluminum that I think fit this purpose. The aluminum was marked with a Sharpie. It was then heated with a torch to the point that the ink disappeared. The demonstrator cooled it slowly, then demonstrated how soft it was.

A candle will do the same. Run it under the aluminum and let the soot coat it, then the torch to burn it off/anneal the part.
Never thought of using a Sharpie. Pretty slick.

 

[46th Georgia]

A candle will do the same. Run it under the aluminum and let the soot coat it, then the torch to burn it off/anneal the part.
Never thought of using a Sharpie. Pretty slick.

Used that method when I worked at the Freightliner dealership in the late 70's in order to straighten/shrink floors that got wrinkled in jackknifes. But we used a rosebud torch. Works great.

 

[Jim]

But we used a rosebud torch. Works great.

Yes, an oxy/acetylene torch set very rich will soot like crazy... perfect for this application. Used that quiet a bit myself.

 

[Jim]

Used that method when I worked at the Freightliner dealership in the late 70's in order to straighten/shrink floors that got wrinkled in jackknifes. But we used a rosebud torch. Works great.

Yes, an oxy/acetylene torch set very rich will soot like crazy... perfect for this application. Used that quiet a bit myself.

The nice thing about using the torch is it's quick and easy. Use the torch to "soot" the part, add a little oxygen to clean up the flame and then use it to heat the part. Quick and easy.

 

[46th Georgia]

The nice thing about using the torch is it's quick and easy. Use the torch to "soot" the part, add a little oxygen to clean up the flame and then use it to heat the part. Quick and easy.

The trick is removing the heat before the panel/part becomes a silver blob on the floor.

 

[Charles13]

I have only used Honda brake line washers for almost 50 years and never had an issue, I buy them 50 at a time

 

[jetmechmarty]

I have only used Honda brake line washers for almost 50 years and never had an issue, I buy them 50 at a time

Nor should you.

 

[bosco659]

I have only used Honda brake line washers for almost 50 years and never had an issue, I buy them 50 at a time

From the dealer? That must be costly.

 

[Charles13]

From the dealer? That must be costly.

Pennies a piece

 

[AUTOMAN]

1200°F is melting range
It will no glow like steel or copper before melting fast.