Plug welded some banjo fittings closed the other day.
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  1. #1
    Join Date
    Oct 2015
    Location
    Joliet, IL
    Posts
    814

    Plug welded some banjo fittings closed the other day.

    I've been working on my 94 4Runner, just replacing the head gaskets so it can run a few more thousand miles before I try to swap in a V8. I about had it all buttoned back up, and tried to reconnect the cold start injector fuel line when it snapped. It's the plastic style line with banjo fittings at both ends. I couldn't find a new one to buy to save my life, and heard they were about $120 if I did find one. I don't trust buying a used one off ebay because they are probably all as brittle as mine. I tried to find a local place that could make custom hydraulic lines and the only one I found doesn't have any hose material approved for gasoline. Then tried to see if I can use AN fittings to replace the banjo fittings but I would have to order a few adapters, and would end up being more than I want to spend and take longer than I wanted. I couldn't find anywhere that had short M8x1.0 bolts to just plug the holes to just remove the line either. So I decided to just make plugs out of the banjo fittings themselves.

    I just cut them off the line with a cutting wheel, and not knowing what kind of steel they were (They did have a zinc coating) I just used some Inconel because I've used that a lot with code welding dissimilar metals. Plus I have some laying around. (I wouldn't have gone out to buy any of I didn't) Came out about as good as I could have hoped. I actually plugged the bolts first, then after looking at it, didn't think the threads would seal the fuel in, so I plugged the fittings too. I've heard a lot of people just disabling the cold start injection when something goes wrong with it without any problems, and it started right up after the fuel lines and rails primed after I got it back together, and no issues starting at all.

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    Last edited by TheBFA; 07-12-2018 at 10:37 PM.

  2. #2
    Join Date
    Oct 2015
    Location
    Joliet, IL
    Posts
    814

    Re: Plug welded some banjo fittings closed the other day.

    Here is one of the banjo fittings. The ring terminals are just acting as soft jaws so I don't mar the gasket surface.
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    Last edited by TheBFA; 07-12-2018 at 10:38 PM.

  3. #3
    Join Date
    Feb 2016
    Location
    Six Mile SC
    Posts
    12

    Re: Plug welded some banjo fittings closed the other day.

    Nice job welding that bolt shut without damaging the threads.
    CG

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