DIY brake pipes

Brake or clutch lines all need replacing at some point. Alisdair Cusick demonstrates how to make your own

ANY hydraulic system on our vehicles will use rigid pipes somewhere. Most commonly it will be the brake system, but metal pipes are also found in clutch systems, suspension levelling systems, cooling and fuel systems. Factory pipework is usually steel, which corrodes in time, failing the MOT test. As such, replacing old pipes has become a routine job on a Land Rover, so it is a useful skill to learn.

New pipes are typically made up from scratch using malleable metal pipe, cut to size, fitted with fixings and then shaped to match the original. The ends of the new pipes need fluid-tight seals to function. That job is done by making a flare on the end of the line. A flare, in basic terms is shaping the end of the tube to provide two sealing faces on the end of the pipe. The relevant fixing then tightens the one face on the fixing side, against the mating face of the caliper, pipe or joint, making a seal.

There are many types of flaring tool, from bench-mounted ones to small hand-held versions. They all work, but with various degrees of repeatability and ease of use. Professionals all love the bench tools, which are faster to use, neater and last a lifetime. Avoid the U-shaped clamp affairs, which are fiddly, cumbersome and a pain. A quality hand-held unit is perfect for the home mechanic, and also enables you to work on lines while the pipes are still on the car – jointing a line, for instance, or re-doing a leaky end if sufficient pipe length remains after cutting.

Anything hydraulic is a vital safety system on the car, so should only be done by someone knowledgeable and confident in their skills, with an eye for detail. It is also an instant telltale of someone’s attitude: if you spot wavy, poorly-made fluid lines on a vehicle, whether part of a restoration or repair, it suggests a similar approach has been taken to maintenance throughout the vehicle. In contrast, neat, factory-looking lines suggests an owner who takes time to do jobs properly.

Pipe shapes and lengths will from vary vehicle to vehicle. A typical job on a Discovery 3/4 or Range Rover Sport is the full length of brake lines front to back (usually done in two halves). As an example in this feature I’m showing a smaller pipe, typical of the Series III pipe between the flexi-hose and the brake cylinder.