Today i met up Nator Socal
; to knock out a quick install for the 4 Piston Brake Kit. Everything went as planned... everything bolted up, no snags.. great quality hardware including grade 8 allens for the caliper to bracket mounting.
The snag? Brake lines... I don't know if someone ordered the wrong brake lines and didn't bother to double check the part#'s on the lines or they never used these on the test vehicle., but the banjo bolt itself, is to long to go into the caliper. How do we know this? The crush washers which are coated silver wont crush.
They won't crush because the washers are to big in diameter for the banjo bolt itself, yet they are to THIN to be crushed; they need to big THICKER. What happens is, CS states the brake line to calp is to be torqued to 15-19 ft lbs. If you try that, then pressurize the system to bleed (powerbleeder) you get this awesome blue flow of fluid pissing out onto the ground from the back of the caliper.
When i say pissing, i mean pissing. So, that tells me the washer didn't crush... lets give it some torque... (directions said 15-19 and it didn't work, so lets see if it works at all
) nope, still nothing... still pissing... more torque? ... sure.. lets take it to the point of no return... Its still pissing Greg... a little more... Nope, still pissing... What could be wrong? Bryce, break the line loose and lets see what's up... Now.. I knew, there was a great chance of this banjo bolt snapping, but it didn't snap until Bryce cracked it loose... It gave us an opportunity to see what happened...
The bolt bottomed out because its too long.. the washers, not being thick enough nor "crushable", are not helping this bolt. Greg and Bryce are very familiar with banjo bolts as they have dealt with some of their snags on BT installs out here. Greg spotted it immediately that the bolt was spewing fluid because it bottomed out and the washers did nothing. It would of taken some serious 15mm washers to stop the leak., but that i still a bandaid fix. Greg suggested that the banjo fitting setup was to small and should be enlarged. Greg pointed to his Bryce's Suzuki and said those banjos are no larger than on the front brake on that bike. What's important here is, i do not want to see anyone installing this kit, then realizing it must be their brake line not installed correctly, doing a hack patch only to end up dead. Hey, we're all pretty smart here, but sometimes people don't want to wait or try to muster a temp solution... i never put it past a human being doing something stupid.
At any rate, it was a real shitty evening and having to put the car back to stock brakes again royally sucked. But not as much as the 2 cans of brake fluid wasted.. Don't ask....
Corksport needs to address these lines. I then want them sent to me for testing. If they are deemed acceptable and safe, ill let them know to send them out to everyone else. This detail is way to important and cannot be overlooked. I am not sure what happened, but as a paying customer on this product, i am pretty disappointed and pissed off.
This is why i ask vendors to send me their stuff for testing before retail. This would of been caught and addressed immediately. It would of saved a whole lot of headache, shipping cost and loss of confidence Corksport now has from me, the owner. I know i told Joel several times in shout, that this kit should be sent to me before retail for this very reason... catching something before are hell breaks loose.
At any rate.. i'm attaching resized images and a direct download to the high res pictures of the issue.