We’ve tried and tested a pile of bending, cutting and flaring gadgets over the years–and we’ve retired almost all of them. Let’s separate the useful tools from the junk.
BENDING
Most bending tools feature a grooved radius, a clamping bar and a moveable bending arm. The main issue: Each tool can bend line to a single radius, meaning multiple benders are needed for bends of different sizes. Plus, in our experience, the low-end tools tend to break quickly. That’s why we usually bend our line around found objects that happen to have the correct radius.
Another style of bending tool uses a spring: The line fits inside, allowing the tool to work like an external mandrel that keeps the line from collapsing. These benders tend to be even less useful than the grooved radius variety, but every now and then one will bail us out.
Our favorite bending tools are found objects with useful radii. In this case, our radius die is just three tubing cutoffs. We’ve also used steel bars, hammer heads, fire extinguishers and welding tanks.
CUTTING
The larger tool is our tubing cutter of choice, while the little one works best for tight spots. Some people advise against tubing cutters because they can work-harden the end of the line and make it more likely to crack when flared. Instead, they advise using an abrasive cutoff wheel. We’ve tried it both ways and have stuck with the cutters.
FLARING
You’re going to need to put an end on your new lines, and having the right setup is essential. For regular brake likes, you need a double flaring tool that makes 45-degree flares. (If you’re working with AN fittings, you need a single flaring tool that makes 37-degree flares.) These 45-degree tools range from cheap to decent to excellent. The cheap ones can be found for as little as $10 and are hard to use successfully. Common issues are slipping lines, uneven flares and self-destruction.
Here’s a decent toolset made by Ridgid, available for about $100. In our two-plus decades of using it, it’s made only the occasional bad flare–usually because we were going too fast and not being fussy.
We recently stepped up to this Universal Hydraulic Flaring Tool Kit from Classic Tube. At about $400, it’s an investment, but in addition to high-quality brake flares, it can make barbed flares for fuel lines plus metric bubble and even O-ring flares. This tool can also flare a line in position; most others require removing the linefrom the car and placing it in a vise. Copies of this tool kit are available for a bit less, but we chose to get ours from Classic Tube because they’re a trusted supporter of the car hobby.
We also recently upgraded to this bonus tool: a tubing straightener from, yes, Classic Tube. It’s another investment at $189, but it makes quick work of straightening tubing coils and delivers very professional results. No more slowly straightening lines with our thumbs.
