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Old 08-19-2013, 02:17 PM
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Diesel911 Diesel911 is offline
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Over the years I have picked US size Copper Crush Washers that were the close to the size (tight) on the Banjo Bolt and used a fine round File to enlarge the ID.

Another method I have used is to slide the to tight washer over a tapered Punch and supported the Washer on a Deep Socket or the Vice Jaws and tapped on the Punch to expand the ID. That distorts the Washer a little but with Copper it does not matter so much.

To soften the Copper you heat it read Hot. It does not matter if you let it cool slowly or cool it fast by dropping it in Water.
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