Making Your Own Brake Lines A Comprehensive Guide

Creating your own brake lines is an essential skill for automotive enthusiasts, mechanics, and DIYers alike. Custom brake lines can lead to better performance and a more personalized touch for your vehicle, whether you're restoring a classic car, upgrading performance parts, or simply replacing old lines. This guide will walk you through the process of making your own brake lines, ensuring safety and effectiveness in your project.

Understanding Brake Lines

Brake lines are critical components of a vehicle's braking system. They are responsible for transferring brake fluid from the master cylinder to the brake calipers or drums, enabling the vehicle to slow down or stop when the brake pedal is pressed. There are mainly two types of brake lines rigid lines and flexible lines. Rigid lines are typically made of steel or copper, while flexible lines are rubber or synthetic materials designed to withstand the pressure and motion characteristic of braking systems.

Tools and Materials Needed

Before you get started, gather the following tools and materials

1. Tools - Tube cutter - Brake line flaring tool - Wrench set - Measuring tape - Wire brush or sandpaper - Brake line bender - Safety glasses and gloves

2. Materials - Steel or copper brake line tubing - Brake line fittings (flare nuts) - Brake fluid - Anti-corrosion coating (optional)

1. Remove Old Brake Lines

Start by safely lifting the vehicle and securing it with jack stands. Locate and remove the old brake lines carefully. Take note of how they are positioned and connected, as this will be helpful when installing the new lines. Use the wrench to disconnect the fittings, and ensure you have a catch pan ready for any residual brake fluid.

2. Measure and Cut

Using a measuring tape, determine the lengths of the new brake lines you will need. Make sure to account for bends and connections, as you want to avoid excess slack. Once measured, use the tube cutter to cleanly cut the new brake line tubing to the desired length. Ensure that the cuts are straight and free of burrs.

3. Flare the Ends

Flanging is an essential step in creating a solid connection for your brake lines. Use the flaring tool to create double flares at both ends of the tubing. Follow the manufacturer's instructions closely, and practice on scrap pieces if necessary to ensure you achieve the correct flare shape. A proper flare ensures a leak-proof connection with the fittings.

4. Bend the Brake Lines

Utilize a brake line bender to shape the tubing according to the original line's path. Take your time with this step to avoid kinks or sharp bends. Tube kinks can lead to weak points that compromise braking performance, so gentle, gradual bends are ideal.

5. Install the New Lines

Now it's time to install your newly created brake lines. Begin by connecting the lines to the brake calipers or drums and then to the master cylinder. Use the appropriate fittings and tighten them using the wrench, being careful not to over-tighten, which can damage the components.

Once all connections are secured, you can re-check your work by visual inspection.

6. Bleed the Brakes

After installation, it’s crucial to bleed the brakes to remove any air bubbles trapped in the system, which can lead to a spongy brake feel. Begin this process at the wheel farthest from the master cylinder and work your way closer. Follow the correct bleeding procedure for your vehicle, and check the brake fluid level periodically during this process.

Safety Checks and Final Thoughts

Once you have completed the installation and bleeding, perform a thorough inspection of all your connections for leaks. Press the brake pedal to ensure that the brake system is functioning correctly before taking your vehicle on a test drive.

Making your own brake lines can be a rewarding project that enhances your understanding of your vehicle’s braking system. It provides an excellent opportunity to ensure that your vehicle's brakes are both efficient and safely tailored to your needs. Always prioritize safety, and when in doubt, consult a professional or refer to vehicle-specific service manuals. Happy wrenching!