I'm putting on new brake lines and doing a 4 wheel Grand Am brake upgrade and when it comes to bolting the brake line to the caliper what's the best way to do it to avois leaks? The copper washers and brake lines are new.

Thanks

Steve

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Some helpful links I've done
How to remove inner door panels, with pics.
How to remove outer door panels, with pics.
How to make rear coil-overs using factory struts, with pics.
How to remove rear bearing hubs, with pics.
How to modify the stock Fiero radio for MP3 players, with pics.
How to come up with the right coolant hoses for that engine swap...With Pics.
Basic Fiero electrical testing "How To" and equipment...with pics.

Thanks for asking the question. I just got my braided lines in and plan the install this weekend. Not planning on changing the calipers though, just the lines.

Looking froward to the replies.

only thing I can say is: make sure the mating surfaces are as clean & smooth as possible

oh - and dont over torque

tho, I am curious if heat is a good addition, to soften the copper?

Yup, make sure the surface is clean/smooth, unless you have new calipers with the grooves still in place. Rebuilt will be sand blasted and the surface will be pitted, making for a bad seal. I also tap on the bolt lightly when doing the final tightening. I think this helps to seat the copper washer.... at least I seem to have good luck that way.

I recently replaced a rear caliper on my 1988. At anything less than the 33 lb-ft it calls for, it will leak. It's scary putting that much torque on aluminum threads, tho. I like the bolt-hammer tap idea.

Neil

I just always use new washers and clean the surfaces as best I can. Torque to spec. I have never had a problem. If you got rebuilt calipers they are more likely to leak there than at the banjo. Rebuilding them yourself is the only way in my opinion.

The factory washers are long life ,the ones with the raised circular rings, these are smash down ,,of course they have been compressed but I have had better luck with them than the new smooth ones .

Pitted banjo bolt thread hole area can be sanded using a known flat surface with sand paper under it,place cloth in hole with grease over it
a pitted hole area can be skimmed with JB weld ...

do not tap hammer on aluminum caliper bolts,unless trying to loosen

[This message has been edited by uhlanstan (edited 01-28-2011).]