Ballpark quote on making a banjo bolt

[Gragson]

I have been asked how much it would cost to make a turbo charger oil feed banjo bolt to specific dims.
I can't do it. The dims don't seem too odd, but I can't find an exact match googling around to buy off the shelf.

M10 flange head cap - 1.25 pitch
35mm length
26mm threaded
9mm straight shank
Material... Thread is going into aluminium sump, shank with oil feed hole would have SS banjo coupling or the usual like.

He wants to go the biggest & safest ID bore for the bolt.
I can get a drawing done and supply the original.

Don't want to waste anyone's time so just wondering up front what we would be looking at ballpark cost and if anyone would be interested in making one or ten?

 

[doubleboost]

Is it a pressure feed pipe

 

[Gragson]

Yes but I don't think its high, an oil pump recirculates the sump oil via galleries. I would need to check this and approx PSI

 

[Gragson]

Pics of original broken part

 

[MattH]

I did one recently. Charged £60 +vat.

 

[MattH]

Before finish milling.

 

[Gragson]

Appreciated! I will let him know for ballpark

 

[MattH]

Looks like the broken one was made with a hand drill.

 

[Gragson]

Thats what I said! Luckily they did not have a go at the sump oil feed gallery

 

[andymfell]

not flange head but is it that vital ?

Goodridge part 992-03-35LZ1 M10x1.5 25mm under head

merlin motorsport https://www.merlinmotorsport.co.uk/p/goodridge-m10x1-25-banjo-bolt-long-in-mild-steel-g-992-03-32lp £2.15+vat

 

[mangocrazy]

I would question why the threaded portion needs to be as long as it is...? M10 x 1.25mm is standard for most Japanes bikes.

 

[Gragson]

Totally agree, its just the dims of the OEM bolt.
If its oil tight it does not need to travel up 25mm of thread.

 

[Gragson]

not flange head but is it that vital ?

Goodridge part 992-03-35LZ1 M10x1.5 25mm under head

merlin motorsport https://www.merlinmotorsport.co.uk/p/goodridge-m10x1-25-banjo-bolt-long-in-mild-steel-g-992-03-32lp £2.15+vat

Thanks for this, appreciated.
I don't have his original oil feed lines / banjo setup so the shoulder on the shank is what I am concerned about as have seen similar and not sure they would make an oil tight fit, hence asking for OE spec.

 

[Pete.]

I've got several of those but all of them are drilled twice for double-banjo fittings. They'd also need the hole opening up.

The shoulder is not significant to sealing because it's all done by the crush washers.

 

[Richard.]

As the original has got that lovely big shoulder on it I’d say the easiest way to do it would be to turn down a m12 cap head to the thread pitch, length etc you state above. At least that way the whole thing baring the hole at the side can be made from one position in the chuck. If that shoulder size is fine then a m12 cap head size will be if that makes sense.
If that’s acceptable then I could make them very quickly.

 

[Pete.]

BTW most turbo oil feeds - especially ball bearing ones - have a restrictor to keep the flow of oil down. Must be a hell of a big turbo to need the hole bored in that one.

 

[Stueeee]

The size of the hole may well have a lot to do with the failure of the bolt. There doesn't look to be more than a few thou' of metal beneath the root of the bolt's thread.

 

[Tom O]

Put some hex stock standing upright machine to size, drill, and threadmill it.

 

[Ruffian]

https://auto.helperformance.com/single-banjo-bolt-m10-x-1-25

Might be worth just buying one to see if it will work before the time and effort making one.

 

[Pete.]

I have a handful of those too.