[copo69]

Thanks for the suggestions but it's already fixed. I sent it to a brake shop where a longer bolt was used to pull the hose down tighter and seal the hose to caliper. He then replaced the bolt with my correct banjo bolt and kept the washer indexed on the caliper. He had a caliper dyno which would keep the caliper pressurized while repairing. Guy does a lot of Porsche and BMW hipo stuff. Sent 'em back with hoses installed. I had used regular caliper bolts that didn't go as far into caliper and the result when I laid the torque to them was pulled threads. The problem was a small nick in the sealing surface that was caused by the tumbling process probably when Stainless Steel Brakes rebuilt them years ago. There is no way to efficiently resurface the seat. Anyway they seal now and the guy was good to deal with. I had started to use the annealing process you described but didn't try it. I think the problem is current copper washers are much harder than older ones and also not quite as thick.