Double Flaring Brake Lines
 

Not really a rotary specific problem - but I need input from someone who has done this before.

I am trying to make hard brake lines for an RX2. The RX2 uses a 10 x 1.25 flare nut SO I cannot just but a pre built brake line and bend it myself. I bought the flare nuts online and have to cut a set of new brake lines I bought, swap the fittings to the correct ones, and then reflare the tube.

Anyhoo, I am having issue with the use of the flaring tools you can get at local parts stores. I have tried two different brand tools from two different stores and have the same issue:

I am using 3/16" brake line and attempting to put a double flare on it. My question is: When I put the 3/16" adapter into the tube for the first flare - is the guide post supposed to be kind of snug? I find that the post is very loose. Because the post is loose, it is very difficult to get the tool to flare evenly - the flare ends up collapsing on one side. Because of the loose post, one of the adapters went so crooked it snapped off the post!

Ive looked at at least three cheap-o flaring tools and they all have the same small post - too small really to fit the inside diameter of a 3/16" brake line. I even tried to up the size and use a 1/4" adapter on a 3/16" line - but the 1/4" adapter is too big - just as I expected.

Yes I cut the tube square. Yes I deburred the tube on the inside and chamfered the outside with a file. Yes the tool that holds the tube is not slipping and the correct amount of tube for the flare is exposed.

I know I should probably just go to a brake shop now and have them flare my tubes and be done.... but its personal now. I have to make a usable double flare - just so I can say I've done it.

http://www.rx7.org/Robinette/flare_brake_line.htm
http://www.youtube.com/watch?v=8iEefnpckGI this video,although it is cheesy and the guy is a little "fumbly" with stuff,it explains it!

^^^ Yeah yeah yeah - seen all those (and more)

Does not address my specific query about the allignment post fitment on the flaring too.

Also, after looking carefully at the shitty tool I bought, it seems defective in that it cannot hold the tube exactly straight. Looks like it was mis-cast or mis-machined. It clamps a tube but the angle is always slightly off.

I'm going to just get a better tool.

it is collapsing as your line is too long. Lenght of the line to be flared should be the same size (thickness) as the die so use the die as your guide.

That isn't the problem. I got that part.

^^^ That guy said it right. Basically Chinese tools are Teh Suxorz. The one I have cannot even hold the tube straight. Its close - but not close enough.

Yea, that's a good video. A little long but very informative. I have a Bluepoint kit and its great. I've used some "off-brand" kits and they wear out fast. I've snapped the little ends off the dies from my bluepoint kit and received free replacements. You can't justify buying off-brand shit that isn't guaranteed for life.

I grease the dies before I insert them into the brake line but they still get stuck. I have to grab them with plies and twist and pull. Any tips to removing dies?

^^^ See, that is what I was asking - the dies should barely fit in the tube?

The kits I am finding - the guide pin on the die is like throwing a hot dog down a hall way. Lots of slop and almost impossible to get everything straight.

The die should be snug. I use a small hammer to lightly tap the dies into place but that's probably unnecessary since they're pressed. Are you sure you're using the right die? The next size up is definitely too big? Are you using a metric brake line kit on american lines?

I'm using the right die for the 3/16" tubing - it stamped 3/16"

I'm using the 3/16" brake tube and tool from Oreileys but the inside diameter is all wrong for the guide post.

I even checked the american 3/16" tube and the metric 3/16" tube (since I was swapping fittings anyway) and the inside diameter was basically the same for both.

I figured it was the tool. I tried to use the same tool on my deuce and a half before and the die fit the inside diameter of the tube but the outside diameter of the deuce's tube was too big for the holder.

If you read the lid on blue point kit it says for thin wall tubing. A lot of the part store line is a thicker wall. That's why dies get stuck. I've had mine snap multiple times on advance auto lines.

I didn't know there was thin and thick walled brake line. Now I know. Thanks!

7Dust- I think this is half the problem. ;)