Bonus Video: How to bend and flare your own brake lines. Details on Tools, Processes, and Tips!

This is a Bonus video to our Jeep WJ rear brakeline replacement video here:    • How to Replace a WJ Jeep Rear Brake L...  

In this video we simply focus on some of the details of tools, processes, and tips for bending and flaring your own lines.

Now, I do admit - if you are just looking to do a single brake line for your WJ, do not have any of these tools, and don't plan to do more in the future - buying a pre-formed brake line is going to be faster and cheaper for you.

For me, I have made lines for vehicles where you can't buy pre-formed lines, or custom applications or other line types. So I've amassed the tools, and a healthy assortment of fittings. I also try to keep a stash of line in stock. So for me, I can often make a full line in the shop without having to go anywhere, and the cost is only the line itself.

So if you're looking to build up the tools and skills to do this, this video gets into more detail of what you'll need, and some tips I've learned over the years.

TOOLS AND PARTS LINKS:

Note that any links going to Amazon will be using our Amazon affiliates links, which means we may get a small commission. Also note that I only link to things I have bought, or would buy as an option. I do not get paid to share links, or promote products - I share what I use or would use only.

BRAKE LINES and TUBE NUTS

Note: As with anything WJ Brake related, do note that there was a change from Tevis to Akebono front calipers for the 2004 model year, which I believe started around April 2003 builds. I don't think this affects any of the brake hard lines, but it does affect the front flexible lines - still always double check any parts we share relating to brakes that they fit your year jeep - even though I do think these specific parts should fit all WJs.

First off, if you are looking to try a pre-formed kit, I'll share one that appears to have good reviews. I don't recall if this is the one we used when we did a pre-formed kit on a 2004 4.0 WJ a few years back. I do recall it went in ok though, it did need some tweaks, and it is a 2-peice kit. Not a bad option if you don't want to bend line.

Fine Lines WIN9951OM Brake Line
https://amzn.to/3kh4Agr

If you prefer to make your own here are some options:

The Nickel-Copper line I used, this also comes with the 3/8-24 tube nuts but NOT the 12mm x 1.0 you need.

4LifetimeLines 25' 3/16 True Copper-Nickel Alloy Non-Magnetic Brake Line Replacement Tubing Coil and Fitting Kit, Inverted Flare
https://amzn.to/3SmPClV

I bought this fitting kit prior which is great if you want to have an assortment of various tube fittings on hand - this includes both the 3/8-24 as well as the 12mm x 1.0 fittings you'll need:

The Stop Shop Fitting Assortment for 3/16 Inch Brake Line Tubing, Inverted Flare & Bubble/ISO flare fittings, Metric & SAE (Pack of 45 fittings)
https://amzn.to/3KBzCu6


Tools:

Eastwood Flaring Tool - this is a great investment if you plan to flare lines yourself...it's not cheap, but it's a wonderful tool. There are some other brands selling this, but Eastwood gets props for their being consistent quality from my experience.

Eastwood Professional Brake Line Flaring Tool Kit | 45° Degree Single Double & Bubble Brake Tubing Flares
https://amzn.to/3SmVXxv

I can't find the tubing cutter I have, I think it was from Harbor Freight, but here's a high quality OTC cutter:

OTC 6514 Mini Heavy Duty Tubing Cutter
https://amzn.to/3Et5Vb8

Tubing Benders:
Will share a few options - if you are investing in tools for this and future work, go as high quality as possible. If you just want a one-time use tool, basic may work...I don't have either of these, because my older benders are not showing up for sale anymore.

High Quality:
Imperial Tool 470FH Triple Head 180 Degree Tube Bender with Roto-Lok Indexing Handle, 3/16", 1/4", 5/16", and 3/8"
https://amzn.to/3ImaDIP

Basic:
Capri Tools Tube Bender, 1/8, 3/16 and 1/4 in. (CP21105)
https://amzn.to/3IkmwPi


Deburring Tool:
AFA Tooling Deburring Tool Kit with 11 High Speed Steel BS1010 Blades
https://amzn.to/3XMHqw5


Flare Wrenches - SAE and Metric Kit:
Sunex Tools 9809A Flare Nut Wrench Set, 1/4"x5/16" - 5/8" - 11/16", 9mm x 11mm - 19mm x 21mm, Fully Polished, 9-Piece (Includes Roll-Case), SAE & Metric
https://amzn.to/3lVqCWL

Kit (flex head SAE):
GEARWRENCH 5 Pc. Flex Head Flare Nut Wrench Set, SAE - 81910
https://amzn.to/3ZtRpbd

Kit (Flex Head Metric):
GEARWRENCH 6 Pc. Flex Flare Nut Wrench, Metric - 81911D
https://amzn.to/3komj5B

Flare Crowsfoot 12mm Metric:
Sunex 971012 3/8-Inch Drive 12-mm Flare Nut Crowfoot Wrench
https://amzn.to/3ITSROF

Kit:
Sunex 9710M 3/8-Inch Drive Metric Crowfoot Flare Nut Wrench Set, Size-10 - Size 19, 10-Piece
https://amzn.to/3lPZesV