Having problems screwing in the banjo bolt. The caliper is in the way. Can I grind or shave the caliper to make room? I've tried routing the braided line all directions. Doesn't work.

Also, is this correct for the washers?

 

I'd get a different hose that fits properly! Not worth the risk.

 

you can get those hose ends with a 45 degree angle

or... a thicker brass washer?

 

There is a lot of material on that caliper. I would, and have grinded away some of it to make the hose fit properly. Those are the proper washers. Good luck.

 

 

Could I swap out the ends?

Russell R4055C Fitting Brake 45 Degree 10mm Banjo Male 3 An Steel Chrome Each | eBay

 

I would either grind the caliper, that is extra casting that can be removed or bend the existing fitting slightly, it is steel. You may get a hose and fitting store to replace the end if the hose is long enough.

 

What calipers do you have, and what banjo did it have on the donor?

 

I ground a half circle to clear, it worked fine.

 

While you may get away with grinding on the caliper to make the line work, somewhere out there is the correct hose for the application. What are the calipers from? Would it be just as simple to get the correct part?

 

It's because my rear calipers are really front calipers. They are 78-88 gm metric calipers. The braided hoses are for that application. I bought both from speedway motors. I switched the front rubber hoses to the rear, and braided to the front. I believe it worked fine.

 

Check for a flare seat in the caliper's port. I would bet it was designed for a tube to screw directly into it. If so, a banjo isn't going to seal.

 

Here's my calipers and braided lines...

1978-88 Replacement GM Midsize Metric Calipers - Speedway Motors, America's Oldest Speed Shop


DOT Braided Stainless Brake Hoses, 1978-88 GM, 10mm-1.5 - Speedway Motors, America's Oldest Speed Shop

 

As long as the banjo bolt doesn't bottom out on the flare, and the copper washers seat flat, it'll seal perfectly.

 

Put two more washers in place to help you gain the clearance. I had this issue on some of the master on my race bikes and adding additional washers fixed it. And trust me if I thought it would cause an issue I would not have done it. Messin with brakes on a bike that I would be hitting 180mph on was not something I took lightly.