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[Andy B]

....

We have to use Time Sert or similar as they are for fixture bolts which are tightened and removed daily. Helicoils simply couldn't hack the torque we were throwing at them on a daily basis. Just my opinion but we found Helicoil more suited to one-off fix, but we need a replacement thread so we use the inserts. 
Horses for courses I suppose. 

Agreed with all of the above. 

[05omegav6]

Worst case, I could ask the people who tweaked the discs to rustle up an adaptor... that said, the place I will try for the longer bolts might also have a ready made solution

[biggriffin]

Try a local hydraulic pipe place eg pirtek, they have different sizes of banjo bolt,and can make up the pipe if you need to change it.be easier than trying to get goodrige to make with out diagram etc and they are in Exeter (nxt to the airport)

[Andy H]

Would it be suitable for caliper use?

Need one to accept an M10x 1.5 banjo bolt. How would I select a suitable one?

Ever so slightly miffed of Sussex...

Shouldn't that be M10 x 1.25?

I don't like timeserts because they can come loose.

I would try Helicoil/Recoil first. Timesert requires a larger tapping size drill (so keep as a last resort)

and a helicoil doesn't  Use a thread lock on a timesert & it's unlikely to come loose 

Is threadlock OK for use with brake fluid?

I am suspicious about the thread pitch - I thought calliper banjo bolts had a fine pitch  Using an M10x1.5 tap might be what destroyed the old thread

[henryd]

Would it be suitable for caliper use?

Need one to accept an M10x 1.5 banjo bolt. How would I select a suitable one?

Ever so slightly miffed of Sussex...

Shouldn't that be M10 x 1.25?

I don't like timeserts because they can come loose.

I would try Helicoil/Recoil first. Timesert requires a larger tapping size drill (so keep as a last resort)

and a helicoil doesn't  Use a thread lock on a timesert & it's unlikely to come loose 

Is threadlock OK for use with brake fluid?

I am suspicious about the thread pitch - I thought calliper banjo bolts had a fine pitch  Using an M10x1.5 tap might be what destroyed the old thread

Me too,1.5 pitch is a pretty coarse thread at that diameter

[05omegav6]

Measured and remeasured... Tapping the hole initially to clean the threads was effortless. The bolt was the one fitted to the Omega caliper.

I might have stripped the thread over torquing it, but the nearside one is far tighter with no issue

[aaronjb]

I'd be inclined to helicoil it and be done, if it's sealing on the flat face with copper washers you should still have enough meat left to seal on without problem.

If you wanted to timesert it I'd be looking to drill & tap appropriate for the insert, apply Loctite 567 (brake fluid safe thread sealant), timesert it, run the face under a mill to make sure it's completely flat and bolt back up with the original banjo and washer. I'd put good money on that sealing..

If I'd bought the little mill for my Myford I'd say bring it over, but I didn't (d'oh) and I don't think a whole caliper waving about in the four jaw chuck on the lathe would be a good idea

[05omegav6]

Helicoil it is specifically an M10 X 1.5 pitch X 1.5D apparently... Being fitted tomorrow.

[ronnyd]

Just checked in Zeus book, M10x1.5 is ISO Metric coarse & M10x1.25 is ISO Metric fine, HTH.

[chrisgixer]

I'd be testing that with full pedal pressure before driving anywhere, personally.

[05omegav6]

I'd be testing that with full pedal pressure before driving anywhere, personally.

Have discussed with the machinist consensus is that the helicoil will be inside the inner diameter of the copper seal, and therefore unable to leak...

Apparently whenever they make summat from aluminium, they fit helicoils from new, as it enables dismantling/refitting. Whereas manufacturers don't bother as, in their eyes, their workshops will never need to undo the fixing

It's not the first set they've done by a long margin

[YZ250]

.......
Have discussed with the machinist consensus is that the helicoil will be inside the inner diameter of the copper seal, and therefore unable to leak.

It's not the first set they've done by a long margin

Hopefully it will be fine Al. Providing the wire coil has something to hang on to, others seem to have been successful in using coils. 
It's not as if they are removed on a regular basis. If they were, an insert would have been a safer bet. Similar example of yours below. 

[05omegav6]

That top pic looks familiar... Will find out later today

[Marks DTM Calib]

Helicoil won't leak and will be stronger than the original thread, it's a fit once or twice application so perfectly suited.

[05omegav6]

Helicoil won't leak and will be stronger than the original thread, it's a fit once or twice application so perfectly suited.

Pleased to confirm, definitely leak free