Author - pim25

It is preferable to read first "Where to get brake hoses? Solution"

What should be done with a longer (over one meter) main line, for example, if it is almost entirely in good condition, already fixed by ten brackets, but only the last 10 cm with a flange are damaged due to corrosion/removal? In this case, I had to come up with an alternative solution.

First of all, I assessed the length of the damaged sections and ordered new copper tubes slightly longer from WP with standard 'male' flanges (to be precise, WP-138) at both ends.

Then, there I bought (also through Exist.ru) adapters (couplings) T-124 'female-female' with the required diameter:

Now it only remained to cut off the unusable sections of the main lines, swage the ends and use the purchased parts for extending the tubes. However, it turned out not to be as simple. As I already mentioned, factory swaging of brake hoses on Japanese cars is a 'double flare' (Double Flare). Considering this, in my situation the swaging tool should meet the following requirements:

1) Perform double flare;

2) Be suitable for working with steel tubes;

3) Have small size and allow work 'in situ'.

If the first point is good – (sets for double flare are available in sales), then the second and third are completely lacking – I did not see swaging tools for steel on sale, and all sets require quite a large space for work or disassembly of tubes.

The best thing I saw on sale was a professional pipe swager Jonnesway suitable for various diameters but only works with copper and aluminum;

What I found to be the most quality online – is an Eastwood tool that flares even hard brake lines made of stainless steel, but only when clamped in vise…

The solution was found quite far from home - among the English, where through eBay was found and bought a Franklin Tools fitting meeting all my requirements for type of swaging, tube material and compactness:

Well, what can I say – an excellently conceived and made tool with which I performed the necessary work on the tubes. Let's consider one such operation in detail.

This is how the brake line under the left front wing looked after breaking when unscrewing a flange, after removing rusted parts:

It is visible that three centimeters are missing until reaching the connection with the hose, however it is impossible to bend the tube due to its passage through the internal arch of the wing.

The total length of this tube, which starts from the distributor of the main brake cylinder, exceeds one meter. In addition, part of it passes through the engine compartment in hard-to-reach places behind the engine – so we decide that it is better to extend it than replace it.

We find an appropriate place in the engine compartment:

And cut the tube by hand with a hacksaw blade:

Lubricate the end of the tube under the flange with anti-corrosion and anti-seize lubricant:

Then screw on the coupling flange:

Afterwards, from a piece of soft wire we make a template for the 'shorty' and bend a new copper tube according to it:

which we cut and then swage, not forgetting to put the flange before swaging! The tool easily handles brake copper, and in the end, we get the necessary tube of the required shape and length

We connect it to the coupling for which additional fixation is made to avoid vibration:

As a result of all our efforts – with the use of appropriate tools – after final assembly from the side of the wheel everything looks great:

Correct swaging of brake line