BRAKE LINE FLARING

Use only brake line tubing approved for automotive use; never use copper tubing. Whenever possible, try to work with brake lines that are already cut to the length needed. These lines are available at most auto parts stores and have machine made flares, the quality of which is hard to duplicate with most of the available inexpensive flaring kits.

When the brakes are applied, there is a great amount of pressure developed in the hydraulic system. An improperly formed flare can leak with resultant loss of stopping power. If you have never formed a double-flare, take time to familiarize yourself with the flaring kit; practice forming double-flares on scrap tubing until you are satisfied with the results.

The following procedure applies to the SA9193BR flaring kit, but should be similar to commercially available brake-line flaring kits. If these instructions differ in any way from those in your kit, follow the instructions in the kit.

1. Determine the length necessary for the replacement or repair and allow an additional ¹⁄₈ in. (3.2mm) for each flare. Select a piece of tubing, then cut the brake line to the necessary length using an appropriate saw. Do not use a tubing cutter.
2. Square the end of the tube with a file and chamfer the edges. Remove burrs from the inside and outside diameters of the cut line using a deburring tool.
3. Install the required fittings onto the line.
4. Install a flaring tool into a vise and install the handle into the operating cam.
5. Loosen the die clamp screw and rotate the locking plate to expose the die carrier opening.
6. Select the required die set (4.75mm DIN) and install in the carrier with the full side of either half facing the clamp screw and the counter bore of both halves facing the punch turret.
7. Insert the prepared line through the rear of the die and push forward until the line end is flush with the die face.
8. Make sure the rear of both halves of the die rest against the hexagon die stops, then rotate the locking plate to the fully closed position and clamp the die firmly by tightening the clamp screw.
9. Rotate the punch turret until the appropriate size (4.75mm DIN) points towards the open end of the line to be flared.
10. Pull the operating handle against the line resistance in order to create the flare, then return the handle to the original position.
11. Release the clamp screw and rotate the locking plate to the open position.
12. Remove the die set and line, then separate by gently tapping both halves on the bench. Inspect the flare for proper size and shape.
13. If necessary, repeat Steps 2–12 for the other end of the line or for the end of the line which is being repaired.
14. Bend the replacement line or section using a line bending tool.
15. If repairing the original line, join the old and new sections using a female union and tighten.