cutting injector return banjo off

5.9 Cummins Fan

5.9 Cummins Fan

Gearhead
Joined
Mar 16, 2009
Messages
444
Like the title says, I am wanting to cut off the banjo that normally goes to the filter housing, but don't want to have rubber hose and hose clamps to tee it into my p pump return. Anyone done this, like put a compression nut or tube nut with a sleeve then flared the return line to 37 degrees, to a AN fitting? I have searched, but have came up empty handed, thanks in advance.
 
I built this for mine on my lathe because I also had problems finding a compression fitting small enough.
IMGP0050.jpg
 
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devon lock said:
I built this for mine on my lathe because I also had problems finding a compression fitting small enough.
IMGP0050.jpg
Click to expand...

Would you be interested in making another one of those for a few extra bucks? Also, anyone know what size the banjo bolt is off the top of their head?
 
5.9 Cummins Fan said:
Would you be interested in making another one of those for a few extra bucks? Also, anyone know what size the banjo bolt is off the top of their head?
Click to expand...

I would like too but can't, last year when I was building my timing gear cover i burnt the motor out of my mini lathe and havn't fixed it yet. Any machine shop would do it fairly cheap i am sure. can't remember the bolt size.
 
One of the guys here punched a hole through the end of an AN male plug and soldered it over the end of the line where he cut off the banjo end. looked pretty clean.
 
AirDog has a part like that in their kits, you could probably call a dealer or AD directly and order one. Based on their installation manual (page 7) I think the part number is 001-4A-1-0008

Or you could get a pressure gauge adapter, plug the 1/8"NPT port and drill and tap the other side to accept the stock banjo bolt.
 
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Cut it off then flare it for 3/16" brake line. I was running 3/16" brake line for the return since I needed mine in two pieces to get it in the s-10. I used a compression fitting at the splice and a brake line flare for the other side.
 
Easiest way is to leave the banjo end on it, buy a pushlock banjo fitting, and screw the stock banjo bolt into an acorn nut.
 
I feel like such an idiot now josh. Thanks. lol

Stack the two banjos on over the other, put the original bolt through and use the acorn nut to tighten it all up. add seals as needed. Wow... I stopped working on that aero setup I sold you because of that. That and it was ugly as hell.
 
Here's the 3/16 brake line flare end coming into the brass 90 and into the blue 90* return fitting:
nx_tappet_cover.jpg


I can't find a picture of the 3/16 compression fitting, but I'll get one tomorrow if I remember.
 
I did something similar to Joefarmer... I used a small brake line tubing cutter to remove the banjo end from the return line. I bought a 3/16'' male inverted flare tube nut, slid it over the end of the line and double flared the line using a simple brake line double flaring kit. I then attached a 3/16'' female inverted flare to 1/8'' NPT male adapter that screws right in to the side of my 6an x 6an x 1/8NPT tee (Jegs fuel pressure gauge adaptor).
 
Why not get a tee, get a cap, make it flat, drill and tap it to the thread size of the return line banjo?
 
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