Emergency Brake Troubles? Learn How to Make New Brake Line in Minutes

Maintaining a reliable braking system is crucial for safe driving. If your brake lines are corroded, leaking, or damaged, it’s essential to replace them. While you can purchase pre-made brake lines, learning how to make your own offers a cost-effective and rewarding solution. This comprehensive guide will equip you with the knowledge and skills to fabricate your own brake lines, ensuring a safe and efficient braking system.

Tools and Materials: A Foundation for Success

Before embarking on your brake line fabrication journey, gather the necessary tools and materials. This ensures a smooth and efficient process:

• Tubing Bender: This specialized tool allows you to create precise bends in the brake line tubing, ensuring proper routing and fit.
• Tubing Cutter: A sharp tubing cutter is essential for clean, burr-free cuts, preventing leaks and maximizing safety.
• Flare Tool: This tool is used to create the flared ends of the brake line, enabling secure connections to the brake components.
• Brake Line Tubing: Choose the appropriate size and material for your vehicle. Copper-nickel tubing is a common choice due to its corrosion resistance.
• Double-Flare Nuts: These nuts are designed to create a secure connection between the brake line and the brake components.
• Brake Fluid: Ensure you have the correct type of brake fluid for your vehicle.
• Safety Glasses: Protect your eyes from potential debris and brake fluid splashes.
• Work Gloves: Keep your hands clean and protected during the fabrication process.
• Wrench Set: A wrench set is essential for tightening and loosening connections during the process.
• Cleaning Supplies: Keep your work area clean and free of contaminants.

Preparing the Brake Line Tubing: A Crucial First Step

Before bending and flaring the tubing, it’s essential to prepare it for optimal performance. This involves:

1. Cleaning the Tubing: Thoroughly clean the tubing to remove any dirt, grease, or debris. This ensures a clean and secure connection.
2. Degreasing the Tubing: Use a degreasing agent to remove any remaining contaminants, ensuring proper adhesion of the flare.
3. Measuring the Tubing: Accurately measure the required length of tubing for each section of the brake line. Remember to factor in the bends and flares.
4. Cutting the Tubing: Use a tubing cutter to make clean, burr-free cuts. Avoid using a hacksaw, as this can create burrs that can cause leaks.

Mastering the Art of Bending: Creating the Perfect Curves

Once the tubing is prepared, it’s time to create the bends. This is where the tubing bender comes into play:

1. Choosing the Right Bender: Select a tubing bender that is compatible with the size and material of your brake line tubing.
2. Setting the Bend Radius: Use the bender’s adjustment mechanism to set the desired bend radius. This is critical for ensuring proper routing and fit.
3. Making the Bends: Carefully bend the tubing, applying even pressure and avoiding kinks or sharp bends.
4. Inspecting the Bends: After each bend, inspect the tubing for any signs of damage or kinks.

Creating Flared Ends: Securing the Connections

The flared ends of the brake line are essential for creating a secure connection to the brake components. This process requires a flare tool:

1. Choosing the Right Flare Tool: Select a flare tool that is compatible with the size of your brake line tubing.
2. Preparing the Tubing: Cut the tubing to the desired length, ensuring a clean and burr-free end.
3. Creating the Flare: Insert the tubing into the flare tool and apply even pressure to create the flare.
4. Inspecting the Flare: After creating the flare, inspect it for any signs of damage or imperfections.

Assembling the Brake Lines: Connecting the Components

Once the brake lines are fabricated, it’s time to assemble them and connect them to the brake components:

1. Connecting the Brake Lines: Thread the double-flare nuts onto the flared ends of the brake lines.
2. Attaching to the Brake Components: Connect the brake lines to the brake calipers, master cylinder, and other components using the double-flare nuts.
3. Tightening the Connections: Tighten the connections securely, ensuring a leak-free seal.

Bleeding the Brakes: Restoring System Functionality

After installing the new brake lines, it’s crucial to bleed the brake system to remove any air bubbles that may have entered during the process. This ensures proper brake performance:

1. Locating the Bleeder Valves: Find the bleeder valves on each brake caliper.
2. Opening the Bleeder Valves: Open the bleeder valves one at a time, allowing brake fluid to flow out.
3. Pumping the Brakes: Have an assistant pump the brake pedal while you hold the bleeder valve open.
4. Repeating the Process: Repeat this process for each bleeder valve until clear brake fluid flows out.

Final Inspection and Testing: Ensuring Safety and Performance

After bleeding the brakes, it’s essential to perform a final inspection and test to ensure the new brake lines are functioning correctly:

1. Visual Inspection: Inspect the brake lines for any leaks or signs of damage.
2. Test Drive: Take the vehicle for a test drive, paying close attention to the brake performance.
3. Checking for Leaks: After the test drive, inspect the brake lines again for any leaks.

Beyond the Basics: Advanced Fabrication Techniques

For more complex brake line installations or vehicles with unique routing requirements, consider these advanced techniques:

• Using a Tubing Bender with a Die: This allows for more precise bends with consistent radii.
• Using a Double-Flare Tool: This creates a stronger and more secure connection.
• Using a Brake Line Flaring Tool: This tool is designed specifically for brake line fabrication and can create different types of flares.

The Future of Brake Line Fabrication: Embracing Innovation

The automotive industry is constantly evolving, and so are the tools and techniques used for brake line fabrication. Here are some emerging trends:

• 3D Printing: 3D printing technology can be used to create custom brake lines with complex geometries.
• Advanced Materials: New materials are being developed that offer improved corrosion resistance and durability.
• Automated Fabrication: Automated fabrication systems can streamline the brake line fabrication process, increasing efficiency and reducing errors.

A Journey of Skill and Safety: Embracing the Challenge

Fabricating your own brake lines can be a rewarding experience, empowering you to take control of your vehicle’s safety and performance. By following these steps and understanding the principles involved, you can confidently tackle this essential maintenance task. Remember, safety is paramount. If you are unsure about any aspect of the process, consult a qualified mechanic.

Basics You Wanted To Know

Q: What type of brake line tubing should I use?
A: Choose copper-nickel tubing for its corrosion resistance. Ensure the tubing size is compatible with your vehicle’s brake system.

Q: How often should I replace my brake lines?
A: The frequency of brake line replacement depends on factors such as driving conditions and environmental exposure. However, it’s generally recommended to inspect them every 5 years or 50,000 miles.

Q: Can I use a hacksaw to cut the brake line tubing?
A: It’s not recommended to use a hacksaw as it can create burrs that can cause leaks. Use a tubing cutter for clean, burr-free cuts.

Q: What happens if I don’t bleed the brakes after installing new brake lines?
A: Air in the brake system can cause spongy brakes and reduced braking performance. Bleeding the brakes removes air bubbles, ensuring proper braking function.

Q: Is it safe to fabricate my own brake lines?
A: Fabricating your own brake lines is safe if done correctly. However, if you are unsure about any aspect of the process, consult a qualified mechanic.