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Bending Stainless Steel Tubing - Bend Your Own Brake Lines

Refreshing Your Car's Steel Tubing Is Easier Than You Think.
By Steve Magnante
Photography by Steve Magnante
Bend Your Own Brake Lines Steve Benoit
Steve Benoit is also a European... 
   
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Bend Your Own Brake Lines Steve Benoit
Steve Benoit is also a European brake-line tool model.
Bend Your Own Brake Lines Tools
Inexpensive double-flaring... 
   
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Bend Your Own Brake Lines Tools
Inexpensive double-flaring kits like this one can be purchased for less than 40 bucks and can handle 31/416-, 11/44-, 51/416-, 31/48-, and 11/42-inch tubing diameters. We've used this KD Tools setup hundreds of times over the past decade.
Bend Your Own Brake Lines Tubing Cutter
Though cheap tubing cutters... 
   
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Bend Your Own Brake Lines Tubing Cutter
Though cheap tubing cutters are available, they don't have proper handles and require extra twisting effort to make cuts. This used one cost us $10 at a swap meet. Its long handle and knob adjuster make cutting a breeze. Watch out for inferior metallurgy on cheap imports. Even thin-wall steel tubing can chip and dull their cutting wheels. They don't last long.
Bend Your Own Brake Lines Reamer
Our tubing cutter has a flip-out... 
   
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Bend Your Own Brake Lines Reamer
Our tubing cutter has a flip-out reamer to scrape out the ridges. In a pinch, you can also use a square file or just about any paring knife as long as it fits and is harder than the tubing material. Just remember to stick it back in the kitchen before anybody notices it's missing.
Bend Your Own Brake Lines Flaring Bar
Before the tube is clamped... 
   
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Bend Your Own Brake Lines Flaring Bar
Before the tube is clamped by the jaws of the flaring bar, the 11/48-inch-thick heel of the flaring adapter (shown) is used to establish the 11/48 inch of tube that protrudes beyond the bar. This is a critical step. Too much tube will cause the flare to collapse or become cocked off center. Insufficient protrusion yields an incomplete flare (junk). Use the heel of the appropriate-size adapter as your guide and you won't go wrong.
Bend Your Own Brake Lines Bell Shape
The pressure from the yoke's... 
   
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Bend Your Own Brake Lines Bell Shape
The pressure from the yoke's pointed swivel and flaring adapter against the flaring bar forms the tube end into a bell shape. You're halfway done at this point.
Bend Your Own Brake Lines Flaring Adapter
Once the flaring bar is clamped... 
   
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Bend Your Own Brake Lines Flaring Adapter
Once the flaring bar is clamped tightly around the tube, the stem of the proper size flaring adapter is inserted into the tube as shown. Notice the tapered openings of the flaring bar that support the tubing and help form the needed taper. The other side of the bar has hard, 90-degree openings with no taper. That's the wrong side, don't use it.

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