Sylvie Willis
Fabricating your own brake lines and fuel lines is a gratifying experience, especially if you're restoring an old muscle car. Flaring a 3/8 fuel line is a straightforward process that can be done at home with the right tools. There are a variety of flaring techniques and styles, such as the common US and Japanese inverted 45-degree double flare, and the process requires careful preparation and measurement to ensure a perfect, leak-proof flare.
How to Flare 3/8 Fuel Line
| Characteristics | Values |
|---|---|
| Tools | Tube cutter, tubing bender, flaring tool |
| Steps | Cut the line, clean the inside diameter, bend the tube, flare the tube |
| Techniques | Double flare, 45-degree roll-in, 45-degree inverted double flare |
| Materials | Steel, stainless steel, aluminum, NiCopp, Cunifer, brass |
| Suppliers | Harbor Freight Tools, The Eastwood Company, Classic Tube, Amazon |
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What You'll Learn
Flare tools and how to flare brake lines
Flaring brake lines is a process that can be done at home, but it requires some specialised tools. Flaring tools come in a few varieties, including wingnut, lever, and hydraulic types. The wingnut type is the least expensive, usually costing around $30, but it is difficult to make a good flare with these tools. Lever types are quicker and cost around $200, but they require a bench vise. Hydraulic types are the most expensive, often costing over $300, but they are the best option if you are plumbing an entire car.
If you are only planning on using a flaring tool a few times, you can rent one from an auto parts store. Alternatively, you can buy a budget option for around $40, but these often require multiple attempts.
When flaring brake lines, it is important to start with a perfectly uniform, straight cut on the line. Never use a hacksaw; instead, use a tubing cutter with rollers and a round blade. You can then use a deburring tool to clean the inside of the tube, and a wire brush, fine sandpaper, or Scotch-Brite to clean the outside. Before flaring, make sure to slide the brake line fitting onto the line, as it is easy to forget this step. Lubricate the end of the tube with grease to ensure the die slides on easily.
The Eastwood Professional Brake Line and Tubing Flaring Tool is a good option for those looking for a high-quality tool. It can be mounted on your benchtop vise and used to form 45-degree flares in steel and stainless steel. It comes with five different-sized dies and a carrying case.
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How to cut the fuel line
Cutting a fuel line can be a risky process, so it's important to take the necessary precautions. Before you start, make sure you have a fire extinguisher nearby and that you are working in a well-ventilated area outside.
There are several tools you can use to cut a fuel line. A hacksaw blade or a small tubing cutter can be used to cut metal fuel lines. If you use a hacksaw, it is recommended to use a greased fine-tooth blade. Tubing cutters are available at any hardware store and can cut the tube cleanly and straight without leaving any jagged edges, sparks, or shavings. If you are working with stainless steel tubing, you may want to consider a different tool, as tubing cutters are more suited for softer metals like copper.
If you are cutting a high-pressure fuel line, you may want to consider using a plumbing mini pipe cutter, which has a cutting wheel that rotates around the pipe. This will take longer and require more force than a copper line, but it will get the job done. Before using the pipe cutter, it is recommended to start slowly and create a groove around the tube before increasing the pressure. You can also use an oscillating multi-tool to cut through the line without creating any sparks.
Once you have made the cut, it is important to clean up the inside diameter of the tube to remove any ragged edges before flaring. You can use a tubing cutter to clean the inside of the tube. Additionally, make sure to measure twice and cut once, leaving enough length for bends.
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The 45-degree double flare
To create a 45-degree double flare, you will need to follow these steps:
- Cut the tubing to the desired length and ensure that it is free of any ragged edges.
- Insert the hard line into the correctly-sized opening in the clamping bar of your tool, following the tool's instructions to secure the line.
- Use the tool's forcing cone to create a single flare at the end of the hard line.
- Back off the forcing cone and remove the single flare adapter.
- Tighten the forcing cone a second time to fold the line back on itself and create the second flare, resulting in a perfect 360-degree flare.
It is important to note that any irregularities in the flare are unacceptable as they can lead to leaks and damage over time. The 45-degree double flare provides a stronger connection and a better seal compared to a 37-degree flare, making it ideal for high-pressure systems. However, it requires more force to create a seal, so it is not as commonly used.
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Tube bending
There are a variety of tools available for tube bending, including simple radius tools and lever-action benders. Lever-action benders offer more control over the bend. Spring-type benders are another option, designed for copper and aluminium tubing, and are best for gentle, large-diameter bends.
When it comes to the type of tubing, Poly-Armour® soft steel is a good option as it bends and flares easily and resists rust. Stainless steel is more challenging to flare and requires a good-quality flaring tool. If you're on a budget, a large socket can be used for tube bending, and a tubing cutter can be used to cut the line.
Before bending, it's important to map out your bends and ensure you have the proper fittings in place. Bending brake lines is not difficult, but it takes practice to master the skill. It's also important to take your time to get it right and avoid cockeyed and incomplete flares, which can lead to time loss and leakage.
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Flaring methods
One method is to use a large socket for tube bending, which can achieve bends that a tubing bender cannot. Another method is to use compression fittings to create homemade "barbs" on the steel lines. First, install a compression fitting conventionally, then remove the coupling. Next, cut the compression nut off the hard line, and push the EFI-rated hose past the ferrule. This creates resistance between the hard and soft lines.
When using a flaring tool, it is important to first clean the inside diameter of the tube to remove any ragged edges before flaring begins. You should also ensure you have enough length, including bends, before cutting. A tubing cutter can be used to gently cut the line, by slowly increasing pressure on the disc and line, rotating the cutter in a back-and-forth motion.
Finally, the line fitting should be installed before the flare is created.
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Frequently asked questions
The 72475 and 72485 Hydra-Flare tube flaring sets are designed for forming 45-degree inverted flares and are popular choices for automotive fuel lines.
First, cut the tube with a tubing cutter and clean the inside diameter. Then, set up the flare by extending the line the width of the die. Finally, use the die to roll the walls of the tube into a 45-degree flare.
It is important to take your time and get the flaring process right to avoid leakage. Be sure to use tube fittings that match the shape of the tube seat and flare angles.
