Dave - I don't recall if you posted it or not, but is your brake hard line double flared as it goes into the caliper? If not, it needs to be to create the complete seal.
I didn't post it, but yes, they were double flared. But those seals only barely seeped. The ones at the splitter and MC were the main issues. I take that to be the line from the MC to splitter was short and needed to be coaxed into being in the right orientation for the banjo bolt. Maybe I was asking for too much, but I tested it by having the lever squeezed over night. Then in the morning I felt the joints and they were very wet. Not dripping, but wet enough for me not to like it.
Damn, apparently it's a lot harder to mill these calipers than I thought. Any suggestions?
It's not hard. Clamp the caliper into the deck vise. Rotate the head to the axis of the threaded hole. Use a small diameter end mill, and walk it in to square the mating surface. 6' if the machinist is competent.
Can't get it done? Ship it to me.
That's was I was thinking. But they didn't feel that way. I wanted to say, "just go have lunch for a bit and I'll get it done myself."
Thanks, but right now I'm making a cage for the calipers to bolt on to to make the hole exactly vertical (and the milling surface to be exactly horizontal). If I can't get someone to do it, I'll break into a shop. If that doesn't work and I get arrested, I'll use my one phone call to tell a friend to ship them to you, ha. I really just don't see how it's that big of a deal for these guys. About $200 and a week's time? I don't think so.
---
1978 Honda CB550K
