How to remove the brake line flange nipple form your calipers to fit braided lines

[grotty100]

I have found very little info on this so here it is!

If you want to fit braided lines to your brake calipers, you need to remove the flange nipple from inside the calipers to accommodate a banjo bolt.

http://img515.imageshack.us/img515/4200/p6110993mw8.jpg

http://img265.imageshack.us/img265/3817/p6110996aq1.jpg

http://img175.imageshack.us/img175/9907/p6111000jc7.jpg

http://img360.imageshack.us/img360/583/p6110999tu4.jpg

This is a fairly easy way to do this using a few simple tools. My calipers were already dismantled, but I'm sure you can slightly modify the procedure for calipers that are still bolted together.

You will need a hammer, pliers, screwdriver, 2x small self tapper screws and a drift (I used an old 6 x 60mm bolt).

http://img387.imageshack.us/img387/521/p6111004px0.jpg

http://img387.imageshack.us/img387/1500/p6111007gj6.jpg

The self tapper screws must fit tightly into the centre of the nipple, but not too tight. Screw one into the back by twisting back and forth until it turns quite easily. You need to screw it in about three threads and then back it out to about 1 1/2 turns. Make sure you can remove it quite easily.

http://img511.imageshack.us/img511/9149/p6111005ic5.jpg

Repeat this procedure for the front so that you have a screw in each side of the nipple.

http://img365.imageshack.us/img365/1091/p6111014vw7.jpg

Now take your drift and GENTLY tap the rear screw until the nipple pops through.

http://img365.imageshack.us/my.php?i...6111010iz0.jpg

http://img80.imageshack.us/img80/1738/p6111011gn8.jpg

Remove the screw from the back. You may need to push the nipple gently from the front so that you can unscrew the back.

http://img292.imageshack.us/img292/3286/p6111012cs4.jpg

You should have enough of the front screw protruding to grab with a pair of pliers.

http://img185.imageshack.us/img185/1386/p6111015ue8.jpg

Now pull. Shouldn't take too much effort.

http://img401.imageshack.us/img401/8783/p6111022rj0.jpg

There it is. Make sure you clean out any stray metal shavings with compressed air. Try not to wipe in the bore with a rag because the metal shavings may scratch the polished surface.

http://img401.imageshack.us/img401/1796/p6111021yq7.jpg

Good Luck!
Grotty.

[The Real Roadrunner]

or the other option is to shorten and countersink the bolt to suit, much quicker and easier to do and lets you bolt the std gear back in place if you ever need to.

getting the correct lines made up would also help but doesn't happen as often due to price.

good info though

cheers
linden

[MWP]

Couldnt you just drill it out?
You wouldnt be able to keep the flange, but it would be a lot easier.

[takai]

Yeah, just shorten and countersink the bolts, MUCH easier. Means you can always use either option.

[grotty100]

or the other option is to shorten and countersink the bolt to suit
cheers
linden

It is never a good idea to shorten a banjo bolt. It may even be illegal???

Couldnt you just drill it out?
You wouldnt be able to keep the flange, but it would be a lot easier.

You can't drill out the nipple because it is only lightly pressed in, not threaded (see link below). The drill bit would just grab it and both would spin. Possibly when this happens you could then pull it out, but you couldn't use it again.

Using the method I described, the nipple comes out whole, as shown here:

http://img401.imageshack.us/img401/8783/p6111022rj0.jpg

It can easily be replaced if you ever want reinstall the original lines.

Grotty.

[The Real Roadrunner]

It is never a good idea to shorten a banjo bolt. It may even be illegal???

Grotty.

how do you figure?

provided you only shorten it the amount needed then there is no problem. it would have the same if not more thread than the std fitting which seem to have 3-4 threads missing before the inverted seat, therefore i see no difference.

done it to over 30 different cars and havn't had a problem yet. and it only takes 5mins.

cheers
linden

[grotty100]

how do you figure?

provided you only shorten it the amount needed then there is no problem. it would have the same if not more thread than the std fitting which seem to have 3-4 threads missing before the inverted seat, therefore i see no difference.

done it to over 30 different cars and haven't had a problem yet. and it only takes 5mins.

cheers
linden

Removing the nipple only takes about 5 minutes as well (unless you're taking photos), so yes I see no difference too........

I personally prefer to remove the part, but hey, we're all entitled to our own opinions.
Grotty.

[grotty100]

Here's some photos of the braided lines fitted to the calipers:













Grotty.