So as the title says I have had issues with a really significant leak, but I'll explain how this started.

Originally my power steering pump was making noise and I figured it needed to be replaced. I sourced a replacement pump and began the to swap it in. I got half way through and realized I would need new copper washers for the banjo bolt on the pump, but I needed to drive the car so I slapped it together anyways. Needless to say I had a slight leak. I ordered new washers and put them in but as I was tightening the banjo bolt I felt the pump strip. So I purchased a second pump, and as I went to replace it I saw that the pump was in perfect shape and it was actually the banjo on the high pressure line that had crushed. Instead of having flat matting surfaces they were now concave. To replace the high pressure line is quite a chore and it's going to run me around $500 for parts. I'm trying to think of any possible ways I can fix the banjo. I was contemplating putting JB weld on the sealing surfaces, letting it dry, and sanding it flat. Either that or reassembling and slobbing the whole thing with JB weld seeing as the high pressure line is screwed now anyways. I don't like doing hack jobs but I also think having to spend 500 to replace a banjo is insane.

The only thing I can think of that wouldn't be super sketchy would be to find a new banjo and solder it in. However, I have no idea where I would find one with the correct dimensions. Any thoughts?

 

Use a torque wrench next time, sound like you over tightened and smashed the banjo.

Other than new, I would check junk yards for replacement lines. Better to replace it with used OEM parts than to clugy together some ghetto JB weld that will probably blow out under the high pressure anyway.