TDCTDI
Samba Advocatus Diaboli
Joined: August 31, 2013
Posts: 13289
Location: North Carolina
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 Posted: Tue Apr 06, 2021 2:12 pm Post subject: Brake line fabrication “how to” |
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I thought that I’d share my technique that I’ve perfected over the years on how to make new brake lines out of bulk 3/16” SAE line & cheapie flaring kit commonly available at FLAPS since it’s somewhat difficult to to find the correct metric line & bubble flaring kit. (Warning, This will be a long post.)
I prefer to use the factory 11mm flare nuts to avoid issues later (like needing to replace a hose & not having the proper size wrench because it doesn’t match the rest.). Since it has already been determined that the lines were incorrect on this beast, I Shanghai’d some lines off of a parts car. I know, why not just use those lines?  Because lines from a Beetle are about 1.5” too short.
Anywho, I started by cutting the ends off the line to remove the fittings.
I then took the remains of a roll of tubing & straightened it out by pushing it down on a flat surface.
Once straight, I slid a flare nut on (don’t forget this, especially if you have already flared the other end). 
To make a traditional or double flare, you use this side of the clamping bar.
However, to recreate the bubble flare as best as possible using this tool, I use the back side to get a sharper profile.
The die also has a step in it to use as a guide to measure how much the line should protrude beyond the clamping bar.
However, since I am not using it as intended, I have found that the line needs to be about 1/2 again further out,
I then grease up the die.
An insert it into the line & slip the forcing bar over it.
I stop tightening it just shy of the clamping bar.
This allows a bit of “squish” so that the flare will crush & assume the correct shape as it is tightened into the master cylinder or brake hose.
Once flared, I remove the line & it usually is slightly deformed by the clamping bar. (You have to make sure that the clamping bar is really tight to ensure that the line doesn’t slip out while you are trying to form the end.)
I then use a pair of parallel jaw pliers to reshape the line by twisting it around the line until it is concentric again. (You could also use an adjustable wrench.)
Here’s what it looks like compared to an original line...
After bending a soft 90° in the line, I then install it in the master cylinder to see where I need to cut it.
Once cut, I use a drill bit to clean up the ID of the line.
And repeat the process on the other end. (Make sure to remember to install the other flare nut.  )
With that completed, I reinstalled the new line into the vehicle.
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Everybody born before 1975 has a story, good, bad, or indifferent, about a VW.
GOFUNDYOURSELF, quit asking everyone to do it for you!
An air cooled VW will make you a hoarder.
Do something, anything, to your project every day, and you will eventually complete it. |
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