gm metric caliper conversion problems

[hitman]

I am a first time builder and have manged to not kill myself or set my garage on fire...yet. I am building a what can only be called a rat custom t bucket.
I've manged to build my own disk brake conversion in the front and then bought a kit to convert the rears using the same cheap-o metric GM single piston calipers.
My problem- no mater WTF I do to these bass-turds I CAN NOT get the banjo fitting to stop leaking at the caliper. I've searched, read, searched some more, and have taken off these calipers a dozen times and redid the banjo fitting and brake line connection, with new crush washers, thicker crush washer, aluminum crush washers, copper crush washers that I annealed, copper crush washers w/ PTFE high PSI thread dope, all to no avail. I am ready to push it out into the street and beat it with a b-ball bat until I can no longer raise my arms. Aside from swollowing my pride and taking it to a shop and have them deal with it; I am 100% convinced its something simple that I am overlooking and I should be able to fix at my home. Please help me figure this out.....before I lose my mind entirely. Thanks for any / all suggestions

 

[hitman]

sorry

Ok..sorry I dont know how to size this photo. Sweet fancy Moses its huge.

 

[Dirtyrat]

I would probably start looking at the face of the caliper, and the face of the bolt where the sealing surfaces are, and look at how smooth/flat those areas are.

If its just a cast recess, that may be your issue on the caliper side..

 

[RPM]

Two things come to mind, just right off. Your parts are not matched exactly right. Banjo too big for the bolt? Could the banjo have a crack in it?

 

[Dirtyrat]

Two things come to mind, just right off. Your parts are not matched exactly right. Banjo too big for the bolt? Could the banjo have a crack in it?

Those are good points, I have indeed seen the line be too large for the banjo bolt...

 

[Old Iron]

I've seen banjo bolts too long and bottom out before they really pull down tight

 

[hitman]

Thanks for the replys

Those are all good points. The front end I am using SS lines into a banjo then into the caliper. These are the "allstar" brand from Lanes. T junked the aluminum banjo bolts that came with them in favor of the OEM banjo bolt from GM. The rears are OEM rubber lines. I am going to look at the bolts bottoming out before getting tight and go from there. Thanks again.