Stainless steel brake lines are becoming increasingly popular due to their durability and corrosion resistance. However, connecting crimp fittings onto these lines can be a bit more challenging than connecting them to traditional steel brake lines. The key is to use the right tools and to follow the proper steps.
Crimp fittings are designed to create a leak-proof seal between the brake line and the fitting. They do this by compressing the brake line around the fitting. The amount of compression is critical, so it is important to use the correct crimping tool. There are two types of crimping tools: manual and hydraulic. Manual crimping tools are less expensive, but they require more effort to use. Hydraulic crimping tools are more expensive, but they are easier to use and they provide more consistent results.
Once you have the right tools, you can start connecting the crimp fittings to the brake lines. The first step is to prepare the brake line. You will need to cut the line to the desired length and then flare the end of the line. Flaring the end of the line will help to create a better seal between the line and the fitting. Once the line is prepared, you can start crimping the fitting. You will need to insert the fitting into the crimping tool and then crimp the fitting according to the manufacturer’s instructions. Once the fitting is crimped, you will need to inspect the connection to make sure that it is leak-proof.
Selecting the Appropriate Crimp Fitting
The first step in connecting a crimp fitting to stainless brake line is selecting the correct fitting. Crimp fittings come in various shapes, sizes, and materials, so it’s crucial to choose one that is compatible with your brake line and application.
Consider the following factors when selecting a crimp fitting:
- Line size: Crimp fittings are designed to fit specific sizes of brake line. Ensure that the bore size of the fitting matches the diameter of your brake line.
- Material: Crimp fittings are typically made from steel or aluminum. Steel fittings are stronger and more durable, while aluminum fittings are lighter and more corrosion-resistant. Choose a material that meets the requirements of your application.
- Fitting type: There are two main types of crimp fittings: single-flare and double-flare. Single-flare fittings are used with soft brake lines, while double-flare fittings are used with harder brake lines. Select the correct fitting type based on the type of brake line you are using.
- Application: Consider the environment in which the fitting will be used. If the fitting will be exposed to harsh elements, choose one made from a corrosion-resistant material.
The following table summarizes the key factors to consider when selecting a crimp fitting:
| Factor | Description |
|---|---|
| Line size | The bore size of the fitting must match the diameter of the brake line. |
| Material | Steel fittings are stronger and more durable, while aluminum fittings are lighter and more corrosion-resistant. |
| Fitting type | Single-flare fittings are used with soft brake lines, while double-flare fittings are used with harder brake lines. |
| Application | Consider the environment in which the fitting will be used and choose a material that is corrosion-resistant if necessary. |
Preparing the Brake Line
2. Cutting the Brake Line
Precisely cutting the brake line is crucial for a secure connection. Follow these steps:
- Measure and Mark: Determine the desired length of the brake line and mark it using a measuring tape or a line scribe.
- Use a Brake Line Cutter: Employ a dedicated brake line cutter or a hacksaw with a fine-toothed blade for a clean and perpendicular cut. Avoid using diagonal cutters or pliers, as they can crush or deform the line.
- Check the Cut Surface: Inspect the cut end of the line to ensure it’s flat and free of any burrs or deformations. Remove any sharp edges using a fine-grit sandpaper or a deburring tool.
- Round the Cut End: Smoothly round the cut end using a cutting torch, lighter, or a match. This eliminates sharp edges that could damage the crimp fitting.
- Clean the Cut Surface: Thoroughly clean the cut end with brake cleaner or denatured alcohol to remove any oil, dirt, or metal filings. Ensure the surface is free of contaminants before proceeding to the next step.
Recommended Brake Line Cutters for Stainless Lines
| Cutter | Features |
|---|---|
| OTC Brake Line Cutter | Ratcheting action for effortless cutting and a built-in deburring tool |
| Dorman Brake Line Cutter | Hardened steel blades for precise cuts and a comfortable grip |
| GEARWRENCH Brake Line Cutter | Adjustable cutting wheel for different brake line diameters |
Installing the Crimp Ring
The crimp ring is a crucial component that holds the brake line fitting in place. Here’s a step-by-step guide on how to install the crimp ring properly:
- Align the Crimp Ring: Align the crimp ring with the notch on the brake line fitting. Ensure that the ring is facing the correct direction.
- Slide the Crimp Ring: Using a pair of pliers or a crimping tool, slide the crimp ring over the brake line and fitting until it reaches the stop. Make sure the ring is seated properly and not loose.
- Crimp the Ring: Using a crimping tool or a dedicated crimp tool for brake lines, apply pressure to the crimp ring. Crimp the ring until it is tight and flush against the fitting. The crimping process should not damage the brake line or the fitting.
Tips for Crimping the Ring
- Use a clean and sharp crimping tool to ensure a secure crimp.
- Apply even pressure to the crimp ring while crimping.
- Inspect the crimp ring after crimping to ensure it is properly seated and free of any defects.
| Crimp Ring Installation Checklist |
|---|
| – Ring facing the correct direction |
| – Ring properly aligned |
| – Crimp tool applying even pressure |
| – Ring is tight and flush against the fitting |
Cutting the Brake Line to Length
Precisely measuring and cutting the brake line is crucial for a secure and effective connection. Follow these steps to ensure accuracy:
1. Determine the Required Length
Measure the distance between the brake fitting ports on the calipers and master cylinder. Add an additional 6-8 inches of length to allow for bends and curves.
2. Mark the Cutting Point
Use a marker or scribe to mark the measured length on the brake line. Ensure the mark is perpendicular to the line’s axis.
3. Secure the Line and Cut
Secure the brake line in a vise or vice grips to prevent it from moving during cutting. Use a tubing cutter or hacksaw to make a clean, perpendicular cut at the marked point.
4. Deburr and Clean the Cut End
Deburring removes any sharp edges or burrs from the cut end. Use a deburring tool or file to smooth the inner and outer edges. Clean the cut end with a brake cleaner to remove any debris or contaminants.
Recommended Deburring Tools:
| Tool | Description |
|---|---|
| Brake Line Deburring Tool | Specifically designed for deburring brake lines, featuring a blade that fits the line size |
| Utility Knife | Use a sharp blade with a scraping motion to remove burrs |
| Sandpaper | Wrap sandpaper around a dowel or small file and sand the cut end |
Inserting the Line into the Crimp Fitting
Now that you have the fittings and tools ready, it’s time to insert the brake line into the crimp fitting. Here’s a detailed step-by-step guide to help you do it correctly:
- Choose the Right Fitting: Ensure that the crimp fitting you have is compatible with the brake line you’re using. Different brake lines have different diameters and crimping requirements.
- Clean the Brake Line End: Using a clean cloth or brush, remove any dirt, grease, or debris from the end of the brake line. A clean surface will ensure a proper seal.
- Lubricate the Brake Line End: Apply a small amount of clean brake fluid or a silicone-based lubricant to the end of the brake line. This will help the line slide into the fitting more easily.
- Insert the Brake Line: Carefully insert the lubricated end of the brake line into the crimp fitting. Ensure that it goes in straight and all the way down to the stop.
- Check the Insertion Depth: To ensure a secure crimp, the brake line must be inserted to a specific depth into the fitting. Refer to the manufacturer’s instructions or use a depth gauge to check that the line is inserted to the proper length.
- Inspect the Line for Damage: Once the brake line is inserted, inspect it for any kinks, bends, or damage. If there are any issues, discard the line and start over.
| Insertion Depth | Crimp Fitting Size |
|---|---|
| 1/4 inch | 3/16 inch |
| 3/8 inch | 1/4 inch |
| 1/2 inch | 5/16 inch |
Using the Crimping Tool
Once your components are prepared, you’ll need your trusty crimping tool. This tool is essential for securing the ferrules onto the brake line and the fitting. Follow these steps to use the crimping tool effectively:
1. Select the Correct Crimps
Ensure you have the correct crimps for your brake line and fittings. Different sizes and materials are available.
2. Position the Ferrule
Place the ferrule over the end of the brake line, ensuring it’s flush with the edge.
3. Insert the Fitting
Insert the fitting into the brake line, aligning it with the ferrule.
4. Position the Crimping Tool
Carefully position the crimping tool over the ferrule.
5. Crimp the Ferrule
Squeeze the handles of the crimping tool steadily, applying even pressure to create a uniform crimp around the ferrule.
6. Inspect the Crimp
Once the crimp is complete, inspect it thoroughly for any imperfections or cracks. Pay close attention to the transition between the ferrule and the brake line. The crimp should be secure, free of any gaps, and have a smooth, finished appearance.
| Imperfections to Look for | Solution |
|---|---|
| Cracks or splits in the ferrule or brake line | Recrimp the fitting using a new ferrule and brake line section. |
| Gaps or unevenness in the crimp | Adjust the crimping tool or try recrimping. |
| Bulges or deformities in the brake line | Replace the damaged section of the brake line and recrimp the fitting. |
Crimping the Fitting Securely
This step is crucial for ensuring a leak-proof and durable connection. Follow these steps to crimp the fitting securely:
7. Determine the Number of Crimps
The number of crimps required depends on the size and type of brake line. Refer to the manufacturer’s instructions for the specific number of crimps needed. Generally, a larger brake line requires more crimps.
Here’s a table summarizing the typical number of crimps based on brake line size:
| Brake Line Size | Number of Crimps |
|---|---|
| 3/16 inch | 2 |
| 1/4 inch | 3 |
| 5/16 inch | 4 |
Leak Testing the Connection
After the crimping process is complete, it’s crucial to conduct a leak test to ensure the connection’s integrity.
Materials Required:
**1.** Brake cleaner or rubbing alcohol **2.** Compressed air or a bike pump **3.** Soapy water solution
Steps:
-
Clean the crimped area thoroughly with brake cleaner or rubbing alcohol to remove any contaminants.
-
Connect the brake line to the brake caliper or master cylinder.
-
Apply soapy water solution around the crimped area.
-
Use compressed air or a bike pump to pressurize the brake system.
-
Observe the crimped area for any bubbles or leaks.
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If you observe any bubbles or leaks, disassemble the connection and inspect the components for damage or incorrect assembly.
-
Repeat the leak test until you achieve a leak-free connection.
-
Detailed Leak Testing Procedure:
**a.** Pressurize the brake system to approximately 100 psi (690 kPa). **b.** Apply soapy water solution to the crimped area using a brush or spray bottle. **c.** Hold the brake pedal or lever down for several minutes while observing the crimped area. **d.** If no bubbles appear, the connection is considered leak-free. **e.** Release the pressure and carefully inspect the crimped area for any signs of deformation or damage. **f.** Repeat the leak test as necessary to ensure a secure and reliable connection.
Installing the Crimped Fitting
9. Applying the Crimp Rings
Once the brake line and fitting are prepared, it’s time for the crucial step of adding the crimp rings. These rings are specifically designed to secure the hose to the fitting and ensure a leak-tight connection. Follow these detailed steps to ensure proper installation:
- Select the appropriate crimp rings for your particular fitting and brake line size. Refer to the fitting manufacturer’s instructions for specific ring specifications.
- Carefully slide the first crimp ring onto the brake line, ensuring it is flush against the fitting body.
- Position the second crimp ring over the exposed brake line, leaving a small gap (typically 1/16 to 1/8 inch) between the first ring and the end of the line.
- Lubricate the inner surface of both crimp rings with a hydraulic brake fluid-based lubricant to reduce friction during crimping.
- Insert the brake line and crimp rings into the crimping tool, ensuring they are properly aligned with the tool’s dies.
- Apply gradual and even pressure to the tool to crimp the rings onto the brake line and fitting. Refer to the tool manufacturer’s instructions for recommended crimping force.
- Inspect the crimped connection thoroughly to ensure the rings are fully seated and the connection is secure. Look for any gaps, misalignment, or cracks.
Inspecting and Maintaining the Crimped Connection
Regularly inspecting and maintaining the crimped connection on your brake line is crucial to ensure the integrity and safety of your braking system. Here’s a detailed guide to help you with this process:
Visual Inspection
Visually inspect the crimped connection for any signs of damage, such as:
- Cracks or breaks in the crimp fitting or brake line
- Corrosion or rust on the connection
- Loose or misaligned components
Pressure Test
Connect a pressure gauge to the brake line downstream of the crimped connection. Apply pressure and observe the gauge reading. A sudden drop in pressure indicates a leak in the connection.
Fluid Leakage
Check for any signs of fluid leakage around the crimped connection, especially after applying braking pressure. Even a small leak can compromise the braking system’s performance.
Tightness
Ensure that the crimp fitting is properly tightened. Use a torque wrench to apply the specified torque according to the manufacturer’s recommendations. Under-tightening can lead to leaks, while over-tightening can damage the connection.
Re-Crimping
If any damage or leaks are detected, it is necessary to re-crimp the connection using a new crimp fitting and proper crimping tool. Follow the manufacturer’s instructions carefully to ensure a secure and reliable connection.
Periodic Maintenance
Regular maintenance is essential to prevent issues with the crimped connection. Inspect and tighten the connection as recommended by the manufacturer, typically during routine brake system service or every few years. This helps prevent corrosion, leaks, and other problems before they become significant.
How To Connect A Crimp Fitting Onto Brake Line Stainless
To connect a crimp fitting onto a brake line stainless, you will need the following tools and materials:
- Crimp tool
- Crimp fitting
- Brake line
- Tubing cutter
- Deburring tool
- Safety glasses
Once you have gathered your tools and materials, follow these steps to connect the crimp fitting:
1.
Cut the brake line to the desired length using the tubing cutter.
2.
Deburr the ends of the brake line using the deburring tool.
3.
Slide the crimp fitting onto the brake line.
4.
Position the crimp tool over the crimp fitting.
5.
Squeeze the handles of the crimp tool to crimp the fitting.
6.
Inspect the crimp fitting to ensure that it is secure.
People Also Ask
What is a crimp fitting?
A crimp fitting is a type of fitting that is used to connect two pieces of tubing together. The fitting is made of a metal sleeve that is crimped around the tubing. This creates a permanent connection that is both strong and leak-proof.
What are the benefits of using crimp fittings?
Crimp fittings are a popular choice for connecting brake lines because they are:
- Strong and durable
- Leak-proof
- Easy to install
- Relatively inexpensive
How do I know if a crimp fitting is properly installed?
To ensure that a crimp fitting is properly installed, you should inspect it visually to ensure that the crimp is evenly distributed around the fitting. You should also try to pull the fitting off of the tubing to ensure that it is secure.
