Disc caliper leaking: rough surface

[themechanic]

Can I double stack the new copper washers if the sealing surface of the caliper is too rough to form a proper seal? I've tried two sets of new copper washers, one on top and bottom as required but get the same results. It leaks with a steady drip between the top of the caliper ad the bottom of the hose end. The washers are not crushed all the way around.

I am thinking two washer may do the trick. However, if it doesn't I may remove the caliper and file the surface down a bit.

Thoughts, suggestions, anyone?

Thanks FBBO

 

[RemCharger]

Sounds like maybe the new copper washers are too thin.
You could stack them, but all you're achieving is more thickness.

 

[MIKESPOLARA]

Yes you can but it won't help, or I highly doubt it. I have a special cutter that cuts concentric rings around the hole but they are not something that is readily available. Cost was $300ea out of Canada
Try filing, if not time for a new caliper. If you have air tools a 1" diameter roloc disc on a die grinder might work

 

[themechanic]

I spoke to Cass at DoctorDiff who sells the hoses and calipers. He said the hose end is probably hitting the caliper near the crimp end where the caliper has a raised area to keep the hose from spinning while tightening. He suggested thicker washers (impossible to find with the correct hole size) or grinding the hose end where it's contacting the caliper. He said double stacking wouldn't work.

Going to work on it a bit. Whish me luck.

 

[MIKESPOLARA]

If the hose is hitting the guide on the caliper body you can see that. Multiple washers will work as far as sealing maybe not to fix your problem. Extra washer will not fix an uneven surface because the extra washer would be harder to crush
If the hose is contacting the caliper you grind on the caliper at that spot not the hose

 

[wvmarv]

Those new copper washers are a pain in the butt. I always just cleaned up and used the old ones back in my mechanic days and never had a problem.

 

[Fran Blacker]

If you have an extra one propane torch it red hot for 3 or 4 seconds and make it dead soft.

 

[Billccm]

The intention is to crush the washer and seal. Try these items and it should fix your problem
https://www.camarocentral.com/1969_1978_Camaro_Brake_Hose_Sealing_Copper_Washer_p/brc-38.htm

https://www.camarocentral.com/1969_1971_Camaro_FRONT_Disc_Brake_Flex_Hose_OE_p/brc-2.htm

 

[themechanic]

FIXED IT!

I checked the driver's side that doesn't leak and noticed I had the brake hose on upside down on the passenger's side. These are aftermarket stainless steel braided hoses and the metal hose ends are angled slightly upward. I flipped the hose and installed 2 new washers and no more leak.

Thanks everyone.