Custom Hard Brake Lines - Brake Flaring Tool - 4-Wheel & Off-Road Magazine

Fabrication
The photos and captions here give an overview of building custom hard-lines. Classic Tube was our one-stop source for the parts and special tools required to create professional results at home.

Bending, cutting, and flaring are the three main hard-line maneuvers. Of these, flaring is the most intimidating. SAE 45-Degree Double Flare is standard for most mass-production American automotive applications. It seals in two places: on the outer lip and on the inner 45-degree bevel. Military AN 37-Degree Single Flare usually needs adapters and support sleeves in addition to nuts to mate to automotive components. ISO Bubble Flare is a third style, common on European vehicles.

Proper flaring is crucial for leak-free sealing. Follow the flaring tool's directions. (Never use pipe dope or Teflon tape on flared brake fittings. For optimal sealing between new line and old components, loosen and retighten the nut several times to create a tight seat.)

For long lines, many brake plumbers prefer to bend before flaring. This makes fine-tuning the contours easier.
For long lines, many brake plumbers prefer to bend before flaring. This makes fine-tuning
Flaring begins by choosing the correct adapter for the tubing size. This Made 4 You gauge helps verify tubing diameter.
Flaring begins by choosing the correct adapter for the tubing size. This Made 4 You gauge
The double-flaring tool usually has serrations that hold the tubing in the clamp. Extend the tube through the tool the length of the button adapter's stem.
The double-flaring tool usually has serrations that hold the tubing in the clamp. Extend t

Clean cutting and deburring ensure a good flare. Dull tubing cutters can booger the tubing and work-harden the stainless steel tube. Deburring and chamfering the tube prep it for a smooth, crack-free flare.

As with most things, practice makes perfect. Brakes (and steering) aren't learn-on-the-fly systems, so practice on pieces of scrap tubing until confident enough to do the real deal.

Fabbing hard lines isn't the easiest job, but for custom 4x4s it's one of the most critical.

Recommended Tools
•Tubing bender, a lever-type tool preferable to springs and box wrenches
•Double flaring kit. Some parts stores still rent or loan flaring kits. Fancy kits have hydraulic assist.
•Brake hose clamp
•Pressure bleeder for one-person bleeding
•Line wrenches

Screw down the tool's cone, centering it on the adapter. Continue cranking the cone until the adapter touches the flaring bar.
Screw down the tool's cone, centering it on the adapter. Continue cranking the cone until
With the adapter removed, the cone is cranked down a second time to make the inner flare. Make sure both fittings are installed before flaring the tube's second end.
With the adapter removed, the cone is cranked down a second time to make the inner flare.
Line wrenches are highly recommended for brake fittings. OE steel nuts are particularly prone to seizing in place and are easily rounded off with normal open-end wrenches.
Line wrenches are highly recommended for brake fittings. OE steel nuts are particularly pr

Brake hose clamps are handy tools. They shut off fluid flow, aiding adding custom hard lines for axle swaps and disc-brake conversions.
Brake hose clamps are handy tools. They shut off fluid flow, aiding adding custom hard lin
For one-person brake bleeding, Classic Tube offers the Motive Products Power Bleeder. This pressurizes the master cylinder and adds fluid while the bleeder screws are opened to relieve air.
For one-person brake bleeding, Classic Tube offers the Motive Products Power Bleeder. This
Designed for pros and do-it-yourselfers, Classic Tube's Triple Bender has grooves for 1/4- , 5/16- , and 3/8-inch tubing. Markings are shown in 15-degree increments up to 90 degrees. The adjustable handle accommodates both right- and left-hand bends.
Designed for pros and do-it-yourselfers, Classic Tube's Triple Bender has grooves for 1/4-

SOURCES
Classic Tube 80 Rotech Drive Lancaster NY 14086 800-882-3711 www.classictube.com	Made for You Products PO Box 720700 Pinon Hills CA 92372 760-868-6992 www.made4uproducts.com