Brake Line Tubing: Install Guide Steps

Without proper installation, brake line tubing can damage the safety and efficiency of a vehicle’s braking system. While the process may seem daunting, with the right approach it’s totally doable even for those new to car maintenance. In this guide, we will walk you through the process of using copper-nickel brake lines which are known for their durability and ease of use.

Why Copper-Nickel Brake Lines?

Copper-nickel brake lines have become the preferred brake line material for many. Copper-nickel tubing is more flexible than traditional steel brake lines and is easier to bend and install. It’s also very corrosion resistant, meaning it can withstand harsh weather for long periods without rusting. This is especially critical for vehicles that use roads that are salted during the winter.

Copper nickel fuel line tubing can also be made of copper nickel brake lines because of their resistance to rust and corrosion, which will keep your fuel flow consistent. Quality tubing can extend the life of your braking system by years and it is a worthwhile investment for everyday drivers and car enthusiasts alike.

Getting Prepared with Essential Tools and Materials

Before you begin the installation, you need to have everything you need. Copper Nickel Brake Line Tubing of the proper diameter for your vehicle, a brake line flaring tool, a tubing cutter, and a tubing bender are the key items. Along with the tubing you’ll need brake line fittings to connect the tubing to other components and a set of wrenches to tighten connections. You don’t always need a thread sealant but it can make the seal tighter in some cases.

Particularly important is a brake line flaring tool to make sure the ends of the tubing are shaped to fit into the fittings. Using a high-quality flaring tool can prevent leaks, making the overall braking system more reliable.

·      Removing the Old Brake Line

Begin by safely lifting the vehicle with a jack and securing it with jack stands. Ensure the vehicle is on a level surface to prevent any accidents. Once the vehicle is secure, locate the old brake line you need to replace. It’s best to use penetrating oil on the fittings of the old brake line, as this helps loosen any rusted or stubborn connections.

Use a wrench to carefully detach the old brake line and note how it routed through the vehicle. It will also give you the correct path to install the new line. After removing the old line, clean the connection points thoroughly to make sure the new brake line tubing fits securely.

·      Cutting and Measuring the New Tubing

Once the old brake line is out, measure how long you’ll need the new copper-nickel brake line. You really want to measure slightly longer than the old line, just to make sure you have enough material to work with. Cut the copper nickel tubing to the desired length using a tubing cutter. Cutting smoothly is important to make sure you don’t damage the tubing, as rough edges will lead to leaks later on.

Cutting it, then use a deburring tool or sandpaper to smooth out the edges of the cut tubing. It makes sure the tubing will seat in the fittings correctly, so there is less chance of leaks. A good, clean, even cut is critical to a successful installation.

·      Bending the Tubing

A clean and safe installation requires bending the brake line correctly. The best tool for this job is a tubing bender so that you don’t get kinks and they are nice smooth curves. Bend the tubing to match the original path of the old brake line. However, especially around tight corners, take your time to create smooth bends that won’t restrict the flow of brake fluid.

This part of the process is easier because copper nickel tubing is more flexible than steel. But it’s also important to bend the tubing slowly and steadily to keep its structural integrity. Make sure to periodically check the fit to make sure the tubing will fit correctly with the connection points on your vehicle.

·      Creating a Flare with the Brake Line Flaring Tool

A proper flare at the ends of your copper nickel brake line tubing is crucial for creating a leak-free connection. Place the end of the copper-nickel tubing into the brake line flaring tool, ensuring that the length protruding is suitable for the type of flare you need (usually a double flare for brake lines). Tighten the clamp of the flaring tool to secure the tubing in place.

Follow the instructions of your specific flaring tool to create a flare. The double flare method is typically recommended for brake lines as it provides a stronger and more secure seal compared to a single flare. Take your time during this step—any mistakes can lead to leaks, which compromise the safety of your brake system.

·      Installing the New Brake Line

With the tubing cut, bent, and flared, you’re ready to install the new brake line. Start by attaching the brake line fittings to the ends of the tubing, then carefully route the new brake line through the same path as the old one. Use clips or retainers to secure the tubing in place, ensuring it does not rub against any other components or parts of the vehicle.

After the new brake line is in place, connect it to the brake system using the fittings and use a wrench to tighten them. Don’t over-tighten, which will damage the fittings and lead to leaks. Often a snug fit is all that is necessary.

·      Bleeding the Brake System

Once the new brake line is installed, the brake system needs to be bled to remove any air that may have entered. A spongy brake pedal feel and reduced braking efficiency can result from air in the brake lines. Make sure to use a brake bleeder kit or follow a manual bleeding process to purge all air from the system.

First, bleed the brake caliper closest to the master cylinder and work your way toward the furthest. A helper should press the brake pedal at the same time you open and close the bleeder valve to release air and fluid. Keep repeating this until the brake fluid flows steadily without any air bubbles.

·      Inspect and Test the System

After bleeding the brakes, check all connections for leaks. Look around fittings, flared ends, and the length of the fuel line tubing. If you see any leaks, just tighten the connections a little and check again. When you’re sure the system is leak-free, lower the vehicle and go for a test drive.

Pay attention to how the brake pedal feels and check that the vehicle stops smoothly. If your installation is successful, you should feel firm and responsive brakes. But if the pedal feels soft or the car doesn’t stop properly, recheck for air in the system or a possible leak in the new brake line.

Final Thoughts

Anyone who works on cars should know how to install brake line tubing correctly. Using high-quality copper-nickel brake line tubing not only ensures a longer-lasting braking system but also makes the installation process easier. While it requires precision and patience, the outcome is a safer, more reliable vehicle.

Whether you’re installing fuel line tubing or brake lines, following the proper steps and using the right tools—like a brake line flaring tool—can make a world of difference. By taking the time to do it right, you’ll protect your vehicle, your passengers, and yourself every time you hit the road.