The things we do to Cure the Oil Leaks

[BagONails]

Seems extreme but after all the good work the banjo joint at the oil tank was still not dry.

Took it apart again and measured across the inner and outer joint faces 0.4mm difference in thickness going around!

Cleaned up the smaller outside face to make sure it was flat then turned up a mandrel to provide a square face and a close-fitting, short spigot diameter, drilled and tapped M6, bolted the banjo on and faced off the oil tank side until it cleaned up to create two parallel flat faces. So easy when you have the tools and very satisfying!

The source of the distortion was I think some weld spatter from when a new outlet was put on back in the annals of time probably around doomsday. So the joint face got some needle file attention too at the same time. 

Then I turned up a 2.5mm thick aluminium washer with a very close fit to the outlet stub dia. from a bit of 6061 stock and annealed it.
With this now under the modified banjo and a drop of Loctite we have a dry union yay 

[Topdad]

You forgot to mention an important bit ----- the skill to use those tools  well done !

[BagONails]

You forgot to mention an important bit ----- the skill to use those tools  well done !

Aww shucks! Thanks TD

Like a few of us on here I was lucky enough to do an apprenticeship.  Even though I didn't remain on the tools for long I've never forgotten what I learned and it has turned into a hobby.  I've never gone the full live steam models level of commitment or building engines from scratch etc.  but over the years I've managed to get myself out of trouble and saved a fair few pennies making up bits and doing repairs.  The last 7 years at the Uni its actually been a big part of my job and I've learned new skills and had a very enjoyable time doing it too.  Glad I paid attention back in the day.