Countach brake caliper leaking at banjo

Got my brake hoses after many weeks. Figured a quick job to put back together NOT!
The new caliper I got shows the banjo hole is somehow close to the edge and seems to cause a fluid leak no matter how tight I go. See pictures. copper washers are new too. Just cannot stop the leakage. Now am stuck. What do I do to stop the leak on the lip? It is not like I can go to auto part to get new calipers...


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thanks guy. I thought the flare was the issue. tried different position with banjo caliper off the rotor. No luck.
I am going to take the hose off the car again and clean up the caliper and try on the bench with the banjo and hose and take some more picts. Both Caplipers are leaking.
I have to say this is not the best mechanical break setup I have seen!! Never had issues like this for such a simple job. Never seen banjos setup like this in a place where everything is very tight! I supposed this setup is OEM?

BTW the copper washers are:
OD: 16mm ID: 12mm 1.5mm thick for the banjo bolt head washer
OD: 16mm ID: 10mm 1.5mm thick for the caliper hole seal washer

I had to use a 17mm OD for the bolt head washer but that is ok since it does not fit anything for outer size and the ID is 12mm

 

did this on the bench. mounted the banjo in a flush position. see pictures. The fluid is seeping at the junction of the caliper and the banjo contact, mostly at the side facing us on the picture. Leak is significant. I took a few pictures of the new washer in place, the hole the banjo. Does it mount with some specific side on the caliper? does not look it. That caliper was never used from what I gather. It was old new stock.

 

thks Jim . The new washer is exactly as the old one. So there is a difference in the caliper itself. I'll have to find a thicker washer and try. these caliper are specifically for an e23 BMW. may be they were manufactured slightly differently?

 

I finally finished this today. good eye Jim. I never had a part discrepancy like that before but again I don' do break that often. Indeed the new calipers required 2mm thick washers not the standard OEM 1mm that was there. Tried 1.5 mm but was still leaking.
I could not find 2mm copper metric in that size in the US as it is non standard. Had to buy it from ebay in the UK !! lol. here the only shop would sell me in bulk..

I guess I will get a spare set of front brakes now before any issues.. I wonder also where one can get the OEM banjos because I could not find the same OEM used. I guess the hose banjo setup could be replaced. anyway did not need that.

thanks! that was a fullfilling inexpensive fix using new OEM calipers! Now I need to find a good shop to refurbish my old ones. The piston rubber were melting on both side and some was sticking on the pad thin protective plate.

 

test test

 

Next to front calipers now. Anyone got the BMW front E24 part number? I think that was the bolt one countach caliper.

Also Raymond has a AP caliper setup. I may go with that for the front

http://www.countach.ch/Brakes/index.html

A kit was provided by Carl Bridson with special brackets I think, hoses, banjos and calipers but are the still available? Anyone knows the part number of the APs?
i think over time I am going to shoot for light and safe and keep my OEM rebuild and dry

 

No teasing Chad! lol... talk to me.. short of the $$$$ Brembos, the AP or Wildwood are very good.

Specifically for front (for now):
1. Front Caliper model number
2. pads you use
3. Rotors you use. I suppose the rotors can be used with both widlwood and OEM calipers?
4. banjo/hose setup. I suppose the OEM setup does not fit

By opening the mount hole I suppose you say "take a drill and just go thru the caliper hole". Thus do you re-use the OEM caliper mount bolts ?

 

thanks chad. I am gonna check this out. Will ping you for questions. this will be my late fall project.
i may get the drilled hats from you along with the rings