How to Make Brake Line Flares

Cutting brake lines and making your own flares gives you the ability to make custom brake lines of nearly any length not just those offered by your local auto parts store. Flaring brake lines requires a special flaring tool. These tools can be purchased from a local auto parts store or sometimes borrowed under a loan-a-tool program. Brake lines occasionally need to be replaced after brake component failures. Custom brake lines are often needed for custom hot rods where standard length lines will not fit.

Instructions

1

Cut the tubing to the desired length. Measure carefully, leaving room to screw the nut into the receiving fitting. Using a tubing cutter to carefully cut the tubing. A proper cut should leave a 90 degree angle and very little burring inside the tube. Carefully ream any burr from the inside of the tube using the reamer on the cutting tool or a tapered reamer. The softer the tubing the more pronounced the burr will be.

2

Choose the correct angle for the flare. The most common in automotive brake lines is 45 degrees. In some metric applications or when using Army Navy connections, the correct angle is 37 degrees. When in doubt, consult your professional parts salesman at your local parts store for help identifying what you need.

3

Place the brake line in the hinged flaring bar in the double flaring tool kit. Clamp the line above the bar the same distance as the shoulder of the corresponding adapter. Using the proper insert for the size tubing you are working with, tighten it down gently against the flaring bar forcing the tube into a bell shape. Remove the adapter and then repeat the process creating the double thickness flare at the end of the brake line.

4

Use a tubing bender to bend the brake line to the angles you need and install the line, checking for leaks. Ensure threads are inserted correctly and the flare seats straight and not at an angle.