Do-it-yourself flaring of foreign-made brake pipes. How to flare brake pipes with your own hands? Do-it-yourself brake pipe flaring

Flaring brake pipes is a process that may be needed at any time by someone who has a private car. Of course, the implementation of this and any other procedure associated with technological service and repair vehicle, you can always entrust competent service station professionals, however, numerous drivers go the other way and strive to do everything with my own hands... Any owner has the right to decide who to entrust the maintenance of his vehicle, and many of the problems can be completely resolved on their own.

The purpose of the brake pipes

To have a clear picture of what they are for and what function they perform brake pipes, do not need to be regarded as an independent component, you should get acquainted with the entire car system. The car braking system functions in this way: if it is necessary to reduce the speed or when suddenly braking, the driver unscrews the corresponding lever, and the piston, which is in the main cylinder under great pressure, begins to drive the liquid along special paths.

The very same braking or an absolute stop of the car occurs at the moment of reorganization of the efforts of fluid pressure on the wheel cylinders in opposition brake pads... So, the paths along which the piston drives the fluid to the wheels consist of tubes and hoses. Taking out of the work mode of the part leads to malfunction of the entire braking system, and your car is rendered unusable.

Tube malfunctions

With poor fluid transfer through the tubes, the car is braked with a delay, and the braking distance almost doubles. In addition, in the operation of the system, most often when the brake pedal is pressed, extraneous sounds and some impulse movements occur.

The reason for the damage to the tubes is loss of fluid in the brake system. This loss will lead to overheating of the brake drums and uneven wear on the pads. Another indicator may be the unusual behavior of the car during the period of pressing the lever, namely: the car moves slightly to the side. Of course, this is not a direct cause, however, as experts say, it can indicate a broken tube.

Each motorist must navigate a little in the design of his own car in order to be able in case renovation works eliminate the damage with your own hands, if possible. This applies in particular to the automatic braking system. Often, in case of its malfunctions, it is necessary to expand the pipes through which the liquid passes, when the lever is pressed, from the cylinder to the pads.

You can determine the breakdown yourself in the following situations:

An obvious sign that the tubes are worn out and it is time to do the flaring will be an increase in the braking distance.

The noted problems cause very high damage not only to individual components, but also to the whole system. If the owner wants to protect the car from problems, he must remember that he should be tested at least once a year. brake system.

Expanding pipes is not a very pleasant job, but not very difficult either. The most important thing is that you can flare with your own hands. For a high-quality performance of this work, you need to buy a special device called a "flare tool".

Such a tube flaring kit has a reasonable price, and you can see in it:

• pipe cutter;
• Union;
• ticks;
• stamps.

You can buy a kit at any car store, its cost is a penny compared to the cost of working at a service station.

When purchasing a flaring tool, you need to focus on the manufacturer and cost. It is better not to purchase the cheapest kits, since their quality does not contribute to long-term operation. This method of repair work is cheaper than in a car repair shop.

Utilities are considered to be the culprit for unplanned wear on the pipes. Various chemical reagents and salts, generously scattered to fight, for example, against ice, stimulate the rusting of the alloy several times and reduce the operating time of numerous elements released by the manufacturer. And another factor that makes people often deal with the braking system is the notorious domestic roads. Under load, the tubes are deformed and burst. All together leads to the fact that the components fail quickly.

Self flaring

A cheaper way is to manufacture a homemade device, and not purchase a set for flaring brake pipes. With the desire and minimal ability to work with your hands, there is nothing difficult in this. First you need to make a base (bed) for attaching the parts. You can make it up from two metal corners. Cut the corners of the required length with a grinder, drill 2 holes in them for bolting. This is done in 15 minutes.

Having assembled the bed, it is necessary to make holes for the tube and remove the chamfers on a drilling machine or drill. The most difficult is the production of punches (mandrels). You can order them to a turner.

If you do decide to purchase a flare kit, don't go for the cheapest alternatives on the market. Yes, you can take devices for 800 rubles, but they will certainly be disposable parts. It has been determined that a more or less high-quality set for expanding tubes cannot cost less than 2,000 rubles, or even more.

Often the body of the tube remains intact, but the structure of its head is destroyed. There may be other types of breakdowns:

• coking of the thread as a result of the ingress of liquid on it;
• contamination of joints, etc.

In such situations, if the length permits, you can simply cut off the defective part with a special tool. It is possible to change the entire tube if the following repair is carried out.

Work order

Having figured out how to flare the pipes yourself, provide yourself with the minimum amount of similar work for the future. To do this, install a copper tube in a special place. We assure you that you will need to think about flaring much less often. Even with a very active operation of the machine earlier than 3 years later, you will not need it.

Pros and cons of self flaring

The advantages of self-expanding work include that you don't have to pay someone to work.

Of the minuses, it should be noted that your mechanism may be needed only once. An exception if you buy used cars with huge mileage, which were in bad, negative circumstances or had accidents, and change them quite often.

Doing repairs according to the instructions yourself or entrusting them to professionals, you have to decide personally, but you need to constantly monitor the condition of the entire brake system and pipes.

So, summing up, it can be noted that the work on expanding the branch pipes is not very time consuming and difficult. You need to understand that most of the repair work on a steel friend can be easily performed on your own. And this is very important, because by fixing a malfunction with your own hands, you can not only save money, but also do the job better than any car mechanic. The main thing is to follow the instructions.

Installation of copper pipelines can be done in several ways. One of the most common is the use of the method of soldering individual sections. This makes it possible to achieve tightness, but it is not always practical due to the low rate maximum pressure in system. For heating or water supply systems, it is best to use flaring copper pipes.

Appointment

The essence of this process is to change the geometry of the end part of the workpiece. This is necessary to connect different parts of the pipeline using the socket method, followed by pressing the joint. The device for flaring copper tubes has various parameters and directly depends on the diameter of the product, wall thickness and the required speed of the procedure.

To understand the essence of the process, you can consider the stages of its implementation.

1. Segment preparation: trimming, cutting edge grinding.
2. Determination of the magnitude of the increase in the outer diameter in the connected part of the pipe.
3. With the help of a special tool, a mechanical effect occurs on the end face of the workpiece, as a result of which the inner diameter increases.
4. Installation of another pipe section into the resulting socket. The connection is then secured by soldering or mechanical crimping.

When installing pipelines, you can choose models with ready-made mounting sockets or perform the procedures for their formation yourself.

Factory production

If the length of the copper line is long and does not contain a large number of rotary parts, you can purchase a product with factory flaring. For this, special shafts made of high-strength steel are used. After the pipe is made, its end part is compressed by two rollers. By rolling method increase geometric dimensions products in a certain part of it.

The advantage of factory flaring is compliance with all pipe parameters: wall thickness, socket length and diameter. However, during installation, the dimensions of the finished structures often do not coincide with the required ones. This leads to an increase in substandard cuttings and, as a consequence, a significant increase in the cost of purchasing materials. Therefore, it is recommended to use a copper pipe flaring tool for laying small lines.

Roller forming by yourself

With air conditioner, tap or heating system from copper pipes, a special tool must be used. Before carrying out work, you should decide on the diameter of the line. In this case, the flaring of the copper pipes must be done by yourself.

For plumbing, products with a cross section of 20 to 32 mm are often used. If a heating system is installed, then optimal diameter is from 32 to 40 mm, depending on the parameters of the boiler. For the installation of air conditioners, products up to 16 mm are used.

Based on this, do-it-yourself flaring of copper pipes can be carried out with several types of tools. The main criterion when choosing should be the quality of the resulting socket and the possibility of using replaceable nozzles for pipes of different diameters.

Tool

The easiest way to change the geometric dimensions of the end face is to use a conical cylinder made of solid material. Its outer diameter should coincide with the maximum size of the cross-section of the future socket.

However, without a lot of practice, defects may appear on the pipe walls. If the flaring of copper pipes is done with more mechanical force than necessary, then as a result, the metal may crack. To prevent this, a stop is welded to the end of the cone. But even this is not always a guarantee of the correct work.

An alternative to this method can be the use of a special tool - an expander. It is a cone head, on the surface of which limiters for pipes of various diameters are positioned step by step. By pressing the lever, the bell is evenly expanded to the required level.

For a large amount of work, there are devices with an electric drive. The processes in them take place automatically, which guarantees a high-quality product. The main disadvantage is the price.

Method advantages

If you do the flaring of copper pipes yourself, it is recommended to purchase a special tool. The use of devices not intended for this purpose can lead to significant deterioration of the connection.

The advantages of a professional flaring tool are as follows:

• Uniform thinning of the walls as a result of mechanical stress.
• No breaks or deformation on the pipe surface.
• The speed of work will make it possible to install the highway in a short time.

With a small amount of work, it is not necessary to buy a professional tool. Nowadays, there are many companies that provide rental service for a small fee.

For a vast army of motorists who are accustomed to performing car repairs on their own, the appearance of new tools and devices in the arsenal of those already available is a self-evident inevitability. Today we are talking about repairs, which very often require replacement of brake pipes. These elements are more susceptible than others to external factors, which affects their condition. But they can be replaced only if there is a specialized tool with which the tubes are expanded. No tool - this operation will fail. This means that you still have to go to the nearest car service. Or go to a car dealership to become the owner of another very useful gadget.

The purpose of the brake pipes

Any hydraulic system needs highways through which the liquid is supplied to the working mechanisms. The braking system of a car is no exception, but it has its own characteristics. They are connected both with the design of the brakes and technical characteristics used working fluid, to which very stringent requirements are imposed:

• it should not boil at temperatures exceeding 200 degrees;
• do not lose fluidity in forty-degree frost;
• not be aggressive towards the rubber parts of the brake system;
• do not lead to corrosion.

The last point is especially important for brake pipes, which are an integral part of the vehicle. modern car... Let's consider the principle of operation of a typical braking system.

The algorithm for stopping the vehicle is associated with the following actions:

• the driver, when it becomes necessary to reduce the speed of the machine until it stops completely, presses the brake pedal with appropriate force;
• the pedal rod directly acts on the piston of the master brake cylinder, actuating it;
• the piston, moving in the cylinder, acts on, creating a certain phenomenon;
• liquid, the compressibility of which is close to zero, moves along the highway and acts on the brake cylinders located on each of the wheels;
• the pistons transmit the impulse of movement to the brake pads, which, pressing against the discs, create a braking force, slowing down the rotation of the wheels.

In this chain, brake pipes are an integral part of the hydraulic line along which the working fluid... Their task is to prevent TJ leaks, therefore, the quality of their connection with other elements of the brake system is of particular importance. This is why a technological operation called flaring is used.

Its essence lies in the deformation of the end section of the tube in such a way as to uniformly increase its diameter (the opposite operation, which consists in narrowing the diameter of the tip of the tube, is called rolling). Flaring is needed in order to ensure the most tight connection of the tubes to each other or the tube to the manifold.

Since, as we have already noted, the brake pipes are subject to mechanical stress, they can get damaged, which caused the system to depressurize - in this case, an immediate operation is required to replace them. Normal wear and tear is the more common reason for replacing this brake system component.

The tube flaring procedure itself consists of three stages:

• determination between the tube sheet and the tip of the tube;
• flaring of both tubes and tubesheet;
• removing the damping load from the inner walls of the tube.

Deformation technology requires that the metal brake tube underwent so-called plastic deformation, and the lattice metal was subjected to elastic deformation. To ensure this condition, the grid is made of a harder metal, which makes it possible, after the completion of the flaring stage, to “wrap” the tube completely.

Ensuring the required tightness of such a connection is carried out by using the method of contact pressure formed between the outer surfaces of the contacting parts. In some cases, the technology for joining flared pipe ends involves the use of welding - this method is called combined.

In the factory, flaring is carried out using a special machine equipped with a hydraulic, pneumatic or electric drive, which provides the ability to control the rotation speed. It is up to the drive to ensure the required connection reliability.

When replacing brake pipes, flaring is carried out using a special tool that can be purchased at a car dealer.

When flaring brake pipes is required

Brake fluid that meets a number of the above requirements is highly hygroscopic, that is, the ability to absorb moisture. This is a payback for a unique set of characteristics, which is why the complete tightness of the line is so important. fraught with the fact that under the influence high temperature it significantly increases the compressibility of the fluid. This means that pressing the brake pedal will lead to the actual braking with some delay, which is unacceptable for safety reasons. And the more air there is in the system, the more noticeable the delay will be.

Depressurization is manifested by quite certain symptoms - a significant increase in the braking distance, pedal failures and the appearance extraneous sounds when braking.

Fluid leaks are usually accompanied by overheating of the brake drums, as the boiling point of the fluid diluted with air drops noticeably. As a result, the brake pads begin to wear more intensively and, which is especially unpleasant, unevenly.

Another clear sign of a violation of the integrity of the brake line is the departure of the car from the original trajectory when braking.

Note that breakage of brake pipes (or rather, the need to replace them) can be caused by other reasons:

• deformation and cracks of the hex head;
• clogging of threaded connections;
• coking of the brake fluid at the interfaces.

Not a single car is insured against such troubles, therefore it is so important to periodically (at least once a year) test the brake system as a whole. Diagnostics of the brake line components should be carried out every 50, routine replacement of rubber hoses and pipes is performed every 125 thousand kilometers, and regardless of their condition.

And since the replacement of these elements requires special processing, we will consider how to expand the brake pipe with our own hands and what tools are required for this.

Self flaring

In industrial conditions, special high-strength shafts are used to expand pipes, while the profile of the end of the pipes is formed as a result of their repeated rolling. Such a rolling machine allows deformation to be performed as accurately and evenly as possible.

When self-expanding, they usually use kits that can be purchased online or in specialized stores. This kit includes a pipe cutter, a clamp, and punches with holes. different diameters(metric or inch size designation) for flare work using a taper screw.

Many car owners, in order to flare the brake pipe at home, use a more primitive method that does not require the purchase of the above-described device - a conical blank with the desired angle. If a tube is made of copper (these are not often found now - manufacturers in order to save massively switch to metal), it has sufficient ductility to perform such an operation on their own. But from you it will be required not just strength, but precisely metered efforts when pulling the tip of the copper tube onto the cone. Any misalignment upon impact - and the result may be unsatisfactory: from the rupture of the rolled surface in the place where the stronger impact fell, to jamming of the surface that is too thinned during such processing. So this way can hardly be recommended as acceptable - it should only be used when absolutely necessary.

Much more predictable results are obtained when using an expander. Here, you will also need to use physical force, but the process itself is simplified, since the pipe is pulled onto one of the replaceable nozzles using a rotating handle.

The expander allows you to expand the tube to the required diameter quickly enough, in just one approach, however, even here, one hundred percent result is not guaranteed. The main guarantee of success is the quality of the pipe itself. If it is bad, that is, the walls are not perfectly even (they have different thicknesses in a certain area undergoing processing), then in this case, too, thin walls will stretch more, thick ones less, and as a result, the flaring will not be ideal. Attempts to "put the squeeze on" the connection can end in failure - its breakage or crushing.

The classic tool for flaring brake pipes is a set of rollers made of tungsten carbide materials. The rollers are rolled over the surface of the pipe being processed, each time with increasing force. As a result, flaring is done smoothly, and all those troubles that are typical for more primitive tools are impossible here. Each new revolution of the rollers increases the diameter of the workpiece by a minimum amount, and this gradual stretching is very well tolerated by the metal.

A similar method is applicable even for a non-ideal workpiece, since in the presence of sections with thicker walls, they are rolled out to the required size, while the surface of the tube becomes even and smooth, without any defects and roughness.

Another common method of flaring is the use of a solid cone, which is pressed with a certain force into a tube that has been previously fixed in a vice. The quality of this method is comparable to the use of shafts, but here it is important to stop at exactly that pressing depth, which corresponds to the required flaring diameter.

Undoubtedly, ideal solution would be the purchase of a finished factory-made machine. But if you belong to the category of craftsmen who try to do everything on their own, including rarely used tools, a flare tool for copper pipes can also be made at home. Without this tool, it will not be possible to ensure a reliable connection of the brake pipes.

The main condition is that metal blanks must be strong, this will allow the device to be used for decades. The design of such a flaring machine is quite simple - it is a frame made of two equal-sized corners.

We need the following tools and materials:

• drilling machine;
• sharpening machine;
• Bulgarian;
• corners (100 x 32 x 5 mm., 2 pcs.);
• mandrels (you can make it yourself or ask to grind it from a familiar turner);
• bolts М8 (2 pcs.).

The flaring tool itself is very simple: both corners are fastened using a bolted connection, after which holes are drilled at the base of the bed, at the edge of which a chamfer is made. A tool like this will allow you to perform almost perfect flaring of the brake pipes, regardless of their length.

The pipe processing algorithm is homemade device practically does not differ from the method of flaring using a purchased factory machine:

• we install the workpiece in the holder and fix it in such a way that the outer edge being processed protrudes about 5-6 millimeters beyond the edges;
• we install a cone of a suitable diameter on the tube;
• after wearing the fittings, we make sure that the direction of the thread turned out to be multidirectional (when viewed from the side of the workpiece tip, the thread should be directed away from each other);
• we begin to screw the cone into the workpiece, which will lead to a uniform flattening of the tube edge. You need to work slowly, making sure that the cone does not go deeper than the set value;
• we take out the part, carefully get rid of the burrs.

As a result, we get a neat, high-quality flared part that can be used for its intended purpose. Your first experience may not be very successful, but if you get the hang of it, you can work the edges of the brake pipes just as well as using the factory tools.

Pros and cons of diy tube flaring

There is no doubt that, working for yourself, you will treat all the stages technological process with the greatest possible responsibility and diligence. Of course, in this case, you will not need to go somewhere and pay someone to do such work.

But there are also obvious disadvantages - we have already given the approximate timing of the scheduled replacement of brake pipes. And since they fail relatively rarely, it is quite possible that you will have to use the purchased or self-made tools once, at most twice. However, if you are the owner of a heavily worn car, it is likely that the tubes will have to be replaced much more often.

Do-it-yourself flaring of brake pipes is an easy task, but subject to the availability of a specialized tool. And what is more profitable - to buy it, make it yourself, or still take the pipes to specialists, you must decide for yourself. The main thing is that the braking system of your car is always in perfect condition.

Flaring brake pipes is a procedure that may be required at any time by someone who has own car... Of course, the implementation of this and any other operation related to the maintenance and repair of a vehicle can always be entrusted to qualified specialists at service stations, but many motorists go the other way and try to do everything with their own hands. Each car owner has the right to decide for himself who to trust the maintenance of his vehicle, but many of these issues can be resolved independently.

Learning to self-expand tubes is a snap.

Brake pipe functions

Brake pipes are an integral part of the braking system of any car, which is responsible for stopping it at the right moment. To understand how important such tubes are for the operation of the brake system as a whole, you should at least superficially familiarize yourself with the principle of its operation.

So, the process of stopping the car, for which the braking system is used, consists of the following stages.

• If it is necessary to reduce the speed of the vehicle or to stop it completely, the driver presses the brake pedal.
• The master cylinder piston connected to the pedal is activated and begins to act on brake fluid.
• Under high pressure, communicated by the piston of the master cylinder, the liquid begins to flow through the pipes and hoses into the cylinders of each wheel, acting already on their pistons.
• Under fluid pressure, the pistons act on the brake pads, which are pressed against the brake discs, stopping the rotation of the wheels.

Car brake system diagram

Obviously, brake pipes play a crucial role in the operation of the entire brake system, and if they break, it completely fails. That is why the repair of these elements, which includes the expansion of the brake pipes, should be approached with all responsibility.

When do you need to expand the brake pipes

Through the brake pipes, as mentioned above, high-pressure brake fluid is supplied to all elements of the system. When the throughput of such tubes deteriorates, the entire system begins to work ineffectively, which leads, in particular, to a significant increase in the stopping distance. The fact that the elements of the brake system, including pipes, require diagnostics (and, possibly, repair), may be indicated by the following characteristic signs:

• the appearance of extraneous sounds and pulsating movements when you press the brake pedal;
• free movement of the brake pedal when you press it;
• leakage of brake fluid, which leads to a decrease in pressure and, accordingly, to ineffective braking and intensive wear of the brake pads;
• driving the car to the side when braking (this situation, although it is an indirect sign, can also indicate that the brake pipes need to be repaired).

Old brake pipes in terrible condition should be urgently replaced even if there are no leaks

However, the main sign that the brake pipes do not fully fulfill their functions and require flaring is an increase in the braking distance. Most common reasons deterioration in the performance of the brake pipes are:

• violations in the design of the hex heads with which such tubes are equipped;
• deterioration of the quality and reliability of threaded connections, the ingress of debris or coked liquid into them.

Such malfunctions, negatively affecting the technical condition of individual elements of the brake system, significantly reduce the efficiency of its work. That is why experts and car manufacturers recommend diagnosing it every six months. If you are tied to the mileage, then this procedure must be performed every 50,000 km, and the rubber tubes must be replaced regardless of their technical condition it is necessary every 125 thousand km of the vehicle's run.

Technology features

Car repair, whatever it is associated with, rarely causes pleasant emotions in the car enthusiast. This is also explained by the fact that such an event, as a rule, is associated with certain financial costs. Meanwhile, if we talk about a situation in which it is necessary to expand the brake pipes, the cost of such a procedure can be minimized if you do it yourself.

So, in order to flare the brake pipes with your own hands, you need not only to study in detail the theoretical information on this issue and watch the corresponding video, but also to purchase a special device. The kit for flaring brake pipes, which can be obtained inexpensively at many automotive stores, includes the following tools and accessories:

• pipe cutter;
• a fitting used as a connector;
• ticks.

The flaring kit usually includes a clamp for various tube sizes.

Using such a simple set, to which you need to add a drill (in order to chamfer the ends of pipes), as well as gasoline, which is necessary as a lubricant, you can not only perform high-quality flaring with your own hands, but also save a decent amount of money that would have to be paid to specialists service stations.

When replacing the tube with a new one, first make a copy based on the old one.

Immediately prior to flaring with a brake pipe, perform the following steps.

1. The tube is unscrewed with a tool or manually from the brake cylinder or caliper.
2. By visual inspection, the presence of damage on the surface of the tube is determined. If they are close to its edge, then the tube can be restored, if not, then it must be replaced with a new one.
3. Using a tool such as a pipe cutter, a damaged area is cut from the edge of the tube and the cut edge is processed with gasoline.
4. The cut end of the tube is clamped with pliers and a chamfer is removed in its inner part using a drill with a drill of the appropriate diameter.
5. The section of the inner surface of the tube, where the chamfer was removed, is cleaned of chips. After that, the end of the tube is inserted into a fitting that acts as a connector.

Gently shorten the tube using a special cutter

After all the above steps have been completed, the tube must be flared, for which it is best to use a special machine. The flaring carried out using such a machine is carried out according to the following algorithm.

1. The end of the tube to be flared is inserted into the clamping hole of the machine. In this case, the part of the tube protruding from the clamping mechanism of the machine should be approximately 5 mm.
2. With the help of a special punch, which such a machine is equipped with, the end of the tube is expanded.
3. If it is necessary to expand the second end of the tube, the entire procedure described above is performed in the same sequence.

We squeeze the die with a press, visually monitoring the formation of fungus, and we get a high-quality crimped tube

As a result of flaring with the help of such a device, with the rules and subtleties of work with which it is best to get acquainted with the video, the end of the brake pipe becomes neatly expanded. The use of a special machine allows you to adjust the parameters of such an expansion, because for brake systems used on cars of different brands, they can seriously differ. As a rule, in special kits, with which you can flare brake pipes with your own hands, there is also a template that allows you to monitor the result of a technological operation.

Unfolding the end of the tube using a special knife located on the back of the cutter

Thus, it is not difficult to expand the tubes used in the braking system of a car if you use special tools and devices for this. Performing such a flaring with your own hands, you not only save money, but also fully control the process of performing a technological operation, the results of which determine the performance of your vehicle. In such cases, you should always remember that the car locksmith does not do the job for himself, and therefore treats it accordingly. In order not to worry about the results self repair your vehicle, you must adhere to a few simple recommendations:

• strict adherence to instructions, which can also be video;
• use for flaring only high-quality tools, devices and Supplies;
• strict control at all stages of the implementation of repair measures.

Following these recommendations, you will be able not only to flare the brake pipes with high quality, but also to perform many other work related to the maintenance and repair of your car, without worrying about the result of these activities.

met-all.org

Flaring brake pipes

The braking system of a car is the basis of safety and needs a professional maintenance... After all, the safety of driving a car depends on it. Today we will tell you about the most terrible breakdowns of the brake system, we will describe in detail what the expansion of brake pipes is, what it is for and with what tools it is performed.

Brake system malfunctions

Almost all drivers know that the braking system of a car consists of a control drive, distribution systems and executive (working bodies). All parts of the brake system are connected using brake pipes (lines). Pressurized brake fluid moves through these pipes. In the process of pressing the brake pedal, the pressure on the TJ rises and it acts on the working element of the system, which locks the wheel and completely stops the vehicle.

During the operation of the brake system, the following malfunctions may occur:

• Leakage of brake pipes and pistons, in which the fluid is under pressure.
• Mechanical breakdown of working bodies. This includes all kinds of jamming of the brake cylinders, etc.
• Violation of pedal free play. Such a malfunction constitutes discomfort to the driver when operating the car.

In this article, we will focus on the first malfunction - a violation of the tightness of the connection of the brake pipes with the working mechanisms.

Automotive brake fluid contains acid, which adversely affects sheet metal products. Also, constant exposure environment can cause corrosion on metal parts. In this regard, the joints of the brake pipes with the working parts of the system can corrode and begin to release from the braking system. special liquid... The other side of the problem is the appearance of air in the system. This phenomenon reduces the pressure inside the brakes and contributes to the deterioration braking properties car.

To save money on buying new brake pipes, drivers go to rebuild the old tube, which is very successful. This process is called flaring.

Flaring brake pipes using a set and tool

Flaring is any deformation or change in the shape of the tube, which is subsequently attached to a special product that connects the tube to the working member of the system.

This concept also applies to the braking system of a car. To carry out flaring work, you must have a special flaring kit. It includes a set of accessories such as a cutting device, a deforming device and a set of tools for tapping the brake pipe.

To carry out flaring work, it is necessary to install the car on inspection pit or overpass and immobilize. The brake fluid is drained from the reservoir and the brake master cylinder. After carrying out all the measures, it is recommended to replace it with a new one, so as not to climb under the car again in the future. Unscrew the union of the damaged brake pipe from its seat and then remove it from the handset itself.

Cut off the damaged section of the line, about 5 centimeters. To cut a pipe, you need to install it in a special device and walk the blade around the entire circumference. After that, the cut end of the pipe is processed in order to get rid of irregularities that can disrupt the shape of the pipe, and therefore its tightness of the connection.

After that, fix the end of the pipe in special device and insert the rolling fungus into it. A threaded shaft is placed on top of the fungus, which is attached to another locking device. By turning the lever, the shape of the cut part of the pipe changes. Then, depending on the presence or absence of thread, it is cut on the pipe. In most cases, all brake pipes are manufactured without it.

Place the new end of the tube into the retainer and tighten the retaining nut. Before installing a new tube, it is necessary to clean the sealed part from grease. To do this, it is enough to treat it with acetone or gasoline. After all these measures, the fitting is installed in its place, brake fluid is poured into the system, it is pumped over and after that the car can be used again.

Video - How and how to flare the tips of the brake pipes

This completes the flaring of the brake pipes. As you can see, this is not a complicated procedure and almost any motorist who will have a flaring kit and other garage inventory will be able to handle it.

VipWash.ru

Do-it-yourself flaring of brake pipes, description of the process

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In what cases is it possible to flare brake pipes with your own hands, and is it possible to do such things at all?

We answer right away: such amateur performance is undesirable.

It is temporarily admissible only in emergency, force majeure cases, subject to a number of rules.

1. The car owner must have a thorough mental picture of how the braking system works on his car.
2. He should have experience with this kind of flaring, and not undertake it for the first time.
3. A special factory-made tool must be available; it is not recommended to use various kinds of homemade products.

Now that all the warnings have been made, a little theory.

There are two options for flaring brake pipes:

• flaring in the form of a cone;
• in the form of a fungus.

The usual material for making pipes is copper, less often steel. What are the reasons leading to their damage?

1. Sloppy driving. Sometimes the owner of the car simply tears them up on obstacles.
2. Incorrect operation (kinks, kinks, incorrect fixation, constriction, etc.).
3. Various kinds of chemistry and salt and other reagents with which our services generously sprinkle the roadway in winter. Corrosion is guaranteed over time.

• With sudden braking, the foot on the brake pedal clearly captures the characteristic pulsations, a creak is heard.
• Braking distances lengthens for no reason.
• When braking, the car “drives” in one direction.
• Pedal travel becomes unusual (sometimes more free).
• The drums are heating up or the pads are worn out unevenly.
• Liquid leakage is visually visible.

In all these cases, you need to drive the car into a hole and carefully check the brake system. Perhaps there was a need for an emergency operation to resuscitate the system. What do we mean by flaring? The process of deforming the material of the end of a tube to form a desired configuration. How to do it in real life?

Do-it-yourself practical flaring of brake pipes

First of all, you need a special flaring machine. Preferably in the factory version. The kit includes:

• the machine itself;
• pipe cutter;
• replaceable dies:
• special holder bar.

The algorithm for flaring the brake pipe is as follows

1. The assembly is dismantled.
2. The defective area is removed with a cutter.
3. The working area is degreased (you can use gasoline).
4. The tube itself is fixed with pliers so that its length of about 50 mm is free.
5. A small chamfer is removed from the inside.
6. Put on the fitting.
7. The tube cut is inserted into the machine and flaring is carried out.

You can watch the whole process in this video:

Next, you should assemble the entire system, fill in the brake fluid, pump it over, test it. Special attention- leaks. In conclusion, it is worth adding: if it is possible to entrust this operation to specialists, it is better to dwell on this option. It is necessary to start flaring the brake pipes with your own hands only as a last resort.

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Do-it-yourself brake pipe flaring

When performing work on tuning the brake system, it simply does not work out to do with just replacing the brake drum discs. Carry out a full modernization automotive system braking is possible only by starting to replace the pipeline on the hydraulic brake and completing the process by installing disc mechanisms. Before starting work such as flaring the brake pipe with your own hands, you must prepare the appropriate tool. Let's figure out the situation.

By manufacturers vehicles movement at the moment in order to increase the economic effect and reduce the cost of the car, steel brake pipes are being installed. Although more recently, the equipment of the hydraulic drive of the brake system was carried out using copper pipes, which have the properties of increased corrosion resistance, in contrast to their iron counterparts, and due to this, the machine's overhaul mileage is prolonged. When tuning an automobile braking system is carried out, usually a larger copper tube is installed in the hydraulic drive, which automatically requires replacing all existing fittings in the pipeline.

The most painstaking moment in the modernization process is the cutting of blanks, as well as the flaring of the tubes. During the last procedure, it is necessary to use a special device to significantly facilitate the operation of tuning the brakes. Such a device has a pipe cutter, with the help of which the pipe installed in the hydraulic drive is cut off. It is absolutely not difficult to work with the device and most car owners can handle it. The whole process consists in degreasing the surface of the tube with acetone, after which the workpiece is securely clamped in the device with a small piece of 5 millimeters remaining on top of the gripper. Next, the end of the tube must be processed using a flaring mechanism. After that, the copper tube with a successfully flared end is freed from the grip and two metal fittings are put on it. The next step will be a similar flaring in the device of the second end of the newly clamped tube. After completing all of the above, the copper tube can be installed in the required place of the hydraulic drive of the automotive braking system. We hope that self-expanding the brake pipe will not cause you any difficulties.

Independently and will help in repairing the brake system.

In order to make a do-it-yourself rolling for brake pipes, you will need:
* Locksmith vice
* Angle grinder, cut-off and grinding wheel
* Metal corner 100 mm
* Metal plate 6 mm thick
* Drill for metal with a diameter of 4.5 mm, 6 mm, 10 mm
* Bolt from the car hub
* Welding machine, gaiters, welding mask
* Safety glasses, gloves, earmuffs
* Copper tube 5mm diameter
* Lathe for metal, tooling
* Tap with thread M6 and M12
* A can of matte paint
* Electric drill

Step one.
Clamps a metal corner 100 mm in size in a vice and, using a ruler and a pencil, make markings along which you will need to saw off the workpiece.

We mark about 30 mm from the edge of the corner and saw off using an angle grinder with a cut-off wheel installed in it. When working with an angle grinder, observe safety precautions, wear safety glasses, ear muffs and gloves, and do not forget that the power tool can break free from your hands at any time, so you need to hold it firmly.

Next, we fix the corner in a vise and align the ends with a grinder with an installed emery wheel for grinding, also round off the edges a little so as not to get hurt when working with the tool.

After that, we change the position of the workpiece in a vice and also grind, removing rust and other external defects of the part.

The result is such a surface.

Step two.
We install the part on an anvil or vise and make a punching in the middle with a light blow of a hammer on the core.

At this point, we drip a little technical oil and drill a hole using an electric drill, in the chuck of which a metal drill with a diameter of 5 mm is installed, after that we change the drill by 10 mm.

During the drilling process, do not forget to add technical oil as this will reduce wear on the cutting edge of the drill, which will extend the life of the drill. In the finished hole we cut a thread using a tap, the thread in this case is selected depending on the diameter of the bolt, here we use an M12 bolt from the car hub. It is also important to add lubricant when threading.

Step three.
We measure the required segment for fastening the tube and saw off a part from the corner with an angle grinder.

Next, we clamp two metal blanks, which need to be made from a sheet of metal 6 mm thick, a hole must be made in them in the middle so that half of the diameter falls on one blank, and the rest on the other. In this case, we take a drill with a diameter of 4.5 mm, in the future, you can make various plates with the necessary grooves for any diameter of the tubes.

After that, you need to drill holes in two blanks at once for fastening on a corner, for this we clamp them together with a hand vise, and only then we drill holes, first 4.5 mm, and then a 6 mm drill for metal.

Step four.
To be able to roll the tubes, you need to do the processing of the hub bolt. To do this, first we shorten it using an angle grinder, and then clamp the bolt in a three-jaw chuck lathe on metal and make a groove to a diameter of 2.5 mm, by the way, it is equal to the inner diameter of a copper tube.

For rolling, we grind out a small notch for the cap. As a result, the bolt should look like this.

You need to weld a bar to it, for this you need a welding machine. Be careful when working with the welding machine, and also use personal protective equipment, a welding mask and gaiters.
In order for the tube not to bend and roll evenly during the rolling process, it is necessary to center it.
We take the brake pipe and put it on the tip of the bolt, then place a blank with a groove for the tube under it, and then fix it with a hand vise and begin to outline the drilling sites.

After that, we unclench the hand vise and drill the holes to the end with a drill with a diameter of 5 mm, and then cut the M6 ​​thread in these holes using a tap.

Step five.
Now it remains to give the tool a beautiful look, for this we paint the parts with a spray of hammer paint, having previously protected the thread with masking tape.

The tool is completely ready, which means it's time to test it in action.