Attention: TDR Forum Junkies 
Firstly as a new TDR member, I'd like to say hello to everyone and let you know I'm impressed with all the terrific information available here about our trucks. I've just gone through the installation of Westach EGT/Boost and Fuel Pressure gauges on my new truck and benefited from a lot of the information posted here.
Concerning my Banjo Blues, I mounted Ray's Banjo at the VP and remote mounted the sender on the firewall. A couple of experiences I had that may help my fellow members:
1) I ordered two pre-tapped Banjo's (one as a spare). Neither bolt was correctly tapped for NPT. It seems Geno's is shipping bolts that have no taper; i. e. you'll have to re-tap them for NPT threads.
2) If you have to re-tap your bolts, make sure you have a good 'wide' bottom out tap. I found out not all taps are created equal. My rule of thumb is you need to tap out the hole so that you can hand thread your fitting as deep as the width of the fitting.
3) I've found the Cummins gaskets to be incompatible with Ray's Banjo. Take a look at the shaft to shoulder surface on Ray's Banjo. It's a radial curve. This curve spread and split the aluminum support ring on the Cummins gaskets every time I tried; no I didn't exceed the 18 foot pound torque rating. Examining the factory schrader I took off, the shaft to shoulder is very square; no curves and it doesn't spread or crack the Cummins gaskets. IMHO, this is a significant FLAW in bolt/gasket combination that Geno's is selling
. If you used this combination in your truck, I'd recommend swiping the Banjo/gasket area with your finger and running it past you nose. If you smell diesel I'd bet you have a cracked gasket, if you smell something else I'd recommend you wash your hands 
.
4) Pep Boy's has a washer that mates up to Ray's Banjo bolt without cracking. It's a 1/2" Metal reinforced Rubber drain plug replacement gasket. It's a perfect fit. Oil-Tite makes the gasket and the SKU# is 3749565274. Much stronger that the Cummins washer and it stands up to the radial shaft to shoulder curve on the Ray's Banjo bolt. NO diesel leaks !!!!
5) I tried both the grease gun hose and the Schrader to R-13 service line options for the remote pressure sender installation but wasn't pleased with all the gender benders required. For me, I went simple: Brass 1/8" male NPT to 1/4" fuel line fitting at the Banjo end and the same with a 1/8" NPT female coupler at the Sender end. Fuel hose routed between the two and high pressure Fuel Injection (FI) hose clamps at both ends (solid band clamps). Simple, brass connections, no pfunny hoses, looks stock, and NO LEAKS!
6) If you're wondering, I used 3' of 1/4" fuel line to get from the VP back to the Sender mounted on the firewall. The Gauge reading is absolutely rock solid.
I hope this info is useful and saves some other TDR members some time and hassle
.
Concerning my Banjo Blues, I mounted Ray's Banjo at the VP and remote mounted the sender on the firewall. A couple of experiences I had that may help my fellow members:
1) I ordered two pre-tapped Banjo's (one as a spare). Neither bolt was correctly tapped for NPT. It seems Geno's is shipping bolts that have no taper; i. e. you'll have to re-tap them for NPT threads.
2) If you have to re-tap your bolts, make sure you have a good 'wide' bottom out tap. I found out not all taps are created equal. My rule of thumb is you need to tap out the hole so that you can hand thread your fitting as deep as the width of the fitting.
3) I've found the Cummins gaskets to be incompatible with Ray's Banjo. Take a look at the shaft to shoulder surface on Ray's Banjo. It's a radial curve. This curve spread and split the aluminum support ring on the Cummins gaskets every time I tried; no I didn't exceed the 18 foot pound torque rating. Examining the factory schrader I took off, the shaft to shoulder is very square; no curves and it doesn't spread or crack the Cummins gaskets. IMHO, this is a significant FLAW in bolt/gasket combination that Geno's is selling
. If you used this combination in your truck, I'd recommend swiping the Banjo/gasket area with your finger and running it past you nose. If you smell diesel I'd bet you have a cracked gasket, if you smell something else I'd recommend you wash your hands . 4) Pep Boy's has a washer that mates up to Ray's Banjo bolt without cracking. It's a 1/2" Metal reinforced Rubber drain plug replacement gasket. It's a perfect fit. Oil-Tite makes the gasket and the SKU# is 3749565274. Much stronger that the Cummins washer and it stands up to the radial shaft to shoulder curve on the Ray's Banjo bolt. NO diesel leaks !!!!
5) I tried both the grease gun hose and the Schrader to R-13 service line options for the remote pressure sender installation but wasn't pleased with all the gender benders required. For me, I went simple: Brass 1/8" male NPT to 1/4" fuel line fitting at the Banjo end and the same with a 1/8" NPT female coupler at the Sender end. Fuel hose routed between the two and high pressure Fuel Injection (FI) hose clamps at both ends (solid band clamps). Simple, brass connections, no pfunny hoses, looks stock, and NO LEAKS!
6) If you're wondering, I used 3' of 1/4" fuel line to get from the VP back to the Sender mounted on the firewall. The Gauge reading is absolutely rock solid.
I hope this info is useful and saves some other TDR members some time and hassle
.
Available at hydraulic hose shops?
