How to Perfectly Double Flare Brake or Fuel line Automotive

How to Perfectly Double Flare Brake or Fuel line Automotive


welcome to crazy performance repairs Channel today we are going to address a fuel line leak above me I have a 2008 HHR the guy had a complaint of a fuel line li he said he patched it in order to get the vehicle here and it wasn’t leaking when I pulled it in I’m assuming it’s gonna be a rusted line repair but the lines are rather clean which is a little suspect to me we are gonna go ahead and remove this wrapping and figure out what the problem is and how to actually fix it [Music] okay so I got the cover off here and we can see that he’s got rubber hose in both spots here with a couple of clamps now it is rusted it looks like he tried to clean it up a little bit with some file or something something rough he scratched it really good to try and clean the rust off okay we’re gonna go ahead and loosen these lines up let them leak out into the oil pan here all right so you can see this line here it’s clean on this side and then right on this side there’s a little bit of a rough spot here but that was the cleanest spot because down here is a little rust and then up a little ways it’s just a little bit of rust so we’re gonna hope that we can flare that little section there before I do that I’m gonna share this little tool with you that I just used to cut that line now you notice this dash here and then there’s also these two dashes here this thing otto sets it’s got springs inside here that auto set how hard it applies for the line so you can cut the line without having to keep adjusting the dial here so this line here we got the cleanest spot being over up kind of high so we’re gonna go right here for this just for the sake of showing you guys at least I’m gonna inspect the top side of the line it looks like I see a little rust there give you guys a glance so this thing is gonna move over and now we have that wine lining up with the first line there I’m gonna go a little more because this is a hard line well I didn’t mean to drop the thing but I never adjusted that dial and I was able to cut the line it cut a nice clean cut now I always adjusted a little bit softer than what I probably should it takes a little longer to do the cut but I like that cut better because it leaves less of a burr on the inside that you have to worry about no this line looks pretty good but it looks really rusty there I’m gonna oh yeah I see a nasty rusty spot up higher so we’re gonna have to patch this line a little bit further down I’m gonna go ahead and take a look at that now so I’m gonna go ahead and replace both these lines back up closer to the tank and we’re gonna do it that way because there’s a really sketchy spot up here that’ll show you when I get this down and past the exhaust so a lot of liens require these to disconnect them I do not believe this line does I’m gonna go ahead and take a look inside the heater on here though but I think there’s a tab up on top of this line it is in fact a push tab style I recognize that I took a mirror and shine it up top and I’m able to see that it’s the style where I have to push a tab it releases the clasp inside this line here and then you can pull it out the problem is that tab does not push whatsoever on this vehicle and you might run into this issue as well so I’m gonna give you a heads up on how to address it usually when those tabs do not cooperate it’s because there’s a bunch of dirt and stuff went up in here so you have to do is you have to take your finger and push like this kind of on it and then at the same time an air nozzle of some sort or a cleaner or something and put it in there whatever you have available to try and flush out or clean out whatever debris is caught in there and usually you can get it to release when you do so okay that one was by far one of the worst ones I’ve done in a long time it was really wedged in there now for more information on the line and mechanism you guys can go ahead and click the link above for a better description of how this thing functions okay so I pulled those two lines out and what we have to go with here or work with here is a little bit interesting so this guy was the one that was down was right about there something like that and this is the one that I pulled off first and this part of the lines is not too shabby but unfortunately this is the rust that I saw was right here and I thought okay so I got to go up a little bit higher now and so this guy was like this around this side here and so I cut that off of there so I can see what I’m up against and then I saw this and that’s obviously a problem so oh it’s actually it’s kind of holding oh there that one’s junk I can break that one pretty easily I don’t have one of these but this thing is rotted so I’m gonna have to get a new end for this so this line is gonna be replaced as long as the piece of line that I get to replace it is you have to over repair this as well now this one is not as critical it’s not under any pressure or anything and I’m still debating how I’m gonna go about fixing this all right so after some evaluations of the lines and what’s available today I have decided to go with repairing what I have so this guy here I’m going to end up going rubber hose probably cut it here and then just run a rubber hose down to where the other end of this is where I’ll find a clean spot to cut it and then hook it up that way so that one’s not a big deal all that is is emissions related anyway however this guy here being this rotted right here I have to replace this in so I have this guy here and it is the same size same style so that’s gonna replace that but it has that on both ends so I’m going to be cutting this and then hooking another line up to it so now what we need to do is this is a premade flared line that comes this fitting a flare on one end I’m gonna use this just because vietze I wasn’t gonna buy a whole roll of line just for doing this job so we’re gonna take this guy we’re gonna add a flare fitting to this end now there’s only one true way to make a absolutely perfect flare on the end here and that is to make sure that you forget to put this nut on here you forget to put the flare nut on I guarantee you that flare will be perfect all right so this line itself is a 3/8 line of course I got to make sure that’s on there we’re gonna shove this thing in here when it comes to attaching these you want to pay attention to the position of whatever line you’re on because of leverage you will be able to clamp the line down a lot better if you take advantage of leverage points so you can see my main one closest to this is right here that means that I want to make sure this one is tight and this one is loose to start with so by doing that now I’m gonna utilize the leverage of the full length of this to tighten that down but of course before you ever do that you need to make sure that this line is in the correct position because if I do it right there I’m not gonna make a proper flare it’s gonna be a piece of junk so here is the part that goes in there to do the double flare it’s got like a contour concave area in here to roll the piece and make it the right dimension but to get the height that’s correct most of these flaring tools you use this this thickness here to judge the height of which you want this line to stick out so you can see how the line itself is the same exact height as the thickness of that piece so now we take this guy shove that in there and of course you got to make sure this is tight okay now that’s tight we can try snug in this one up but it’s pretty much useless because you use the leverage of the full length here now you want to take this part of the tool on this particular design I have to open this up all the way and then cradle it this way turn it and then I can bring it over so it’s above that I will put it against that to tighten this down okay now I’m going to kind of move and turn these and slowly just tighten this little at a time wiggling things twisting things trying to make sure that I’m as centered as I possibly can be because if you’re crooked at all it’ll make a band flare so now I’m going to go ahead and reef this thing down it’s gonna be quite tough being it’s a steel line but you will know as soon as you are done doing this because it will just come to a dead stop there it’s to the point where it got really hard really fast just have a little dab more and loosen this up you can see the bubble that’s there a nice really clean smooth bubble now we’re going to take this thing go in that same bubble hole just like we did with the other adapter and we’re gonna do the same thing we’re gonna move this around tightening it a little bit at a time just kind of trying to find the center point now I should be in the center and this last part here is kind of you gotta feel it you have to kind of try to feel for when you’re gonna be bottom note and this one did not take much of a turn I don’t think I think I got it to where I like it so I’m gonna loosen this up take a look so I think I want to go a little bit more this is the part where you really want to take your time and by doing this little spin thing telling you to do you’re really making sure it’s centered and that’s the best resulting flair by doing that okay so no we are going to remove these now I don’t recommend doing this to put them off because you don’t want to over tighten the hell out of these but I’m gonna use this to take them out just because it makes it a lot easier so now you can see that part of it right on the end here has a little bit smashed down and that’s from the clamp clamping down on it the flare itself it’s a really clean smooth even flare all the way around so there is a good flare this fitting goes all the way down and then it will be attaching to this guy but the little teeth on here have now scratched the coating off of this line and so it’s not very well protected now the best thing you can do for such a scenario is anti-seize grease anything you can think of that will displace water or push the water out of the way that is reasonably thick you want to place it on there and that way the water can’t really get into that area it’s very well trying to avoid getting anything in the actual line itself that way you don’t throw whatever you’re putting on there like a nice ease in my scenario down into the fuel system looks like a pretty darn good fit it’s a little bit off but considering its really close to being the right dimension and shape and everything so I think I can feel comfortable putting that in okay so when it comes to putting hard line and hose together I don’t want to just cut this and leave it a smoothen like this to put the hose on because it can slide off if you’re ever doing it on a system with actual pressure it’s good to know so I’m gonna do it anyway but you do just the same thing as if you were to flare the line only when you put this on here you just don’t tighten it as much and you only do it once so instead of doing a full double flare you’re basically doing like half of a single flare okay so as you can see here I have a nice barb it’s basically half literally half of a bubble flare is what I’ve created and when you do so it gives you a nice spot to make sure that the hose clamp isn’t gonna let the hose fly off of here so it’s a really nice fitting to use for creating a hose barb you can see this is still a little bit dirty but it’s nice and clean where I’m gonna put the clamp and the hose up too so that’s kind of my repair there all right so I’m gonna show you guys how I decided to go about repairing this thing as a final final process here so I have this guy throwing over here and that is going to connect to the emissions side of things so it sits like that roughly and that hose will be connected to there but I’m gonna put that on after I get this line in place now you can see I have it going here and I have electrical tape wrapped around it and then before I finish wrapping the tape one to show you there’s our TV between this and that to create a waterproof seal this is probably way overkill just kind of a little step I’m taking to prevent it from corroding because what I’m gonna do next is the part that’s gonna cause it to corrode if we were to have a problem really this thing’s been sitting here for three days and she’s got a dripping gas anyway so these uh I got the zip ties here holding the hose into place I’m gonna go ahead and finish wrapping this and then so I’m gonna take some of this exhaust header wrap type material and I’m gonna wrap it around here now this stuff well collect moisture so I’m gonna also do a secondary thing to try and prevent this from collecting moisture so I’m going way above and beyond on this job to prevent this line from rotting out up here because the last thing I want is to have this guy have a problem with this line this should easily last life the vehicle what I’m planning on is this aluminum ducting tape so I’m gonna take this and I’m gonna go behind the electrical tape and start it about here now the exhaust runs right here and there’s also a little heat shield on the exhaust so I shouldn’t have a problem but just because I have this rubber hose here I want to try and prevent it from getting dry rotted and then heat soaked too badly which is why I’m doing this the fuel going through this pipe will help keep this area cool this will create an insulation barrier to keep a temperature change I just got dripped down again Wow all right and then this guy will prevent the moisture from soaking into this so this will be wrapped right here and the tape will be overlapping from the electrical tape to that to prevent the moisture from getting in there hopefully and then if moisture does get in here somehow hopefully it’ll be prevented from getting in here because of the tape and the art viii so we’re gonna hope like hell I don’t create any pinholes and problems okay one last little step I have left I have this thing wrapped I have a sealed on this end as best I could I took and rolled up a little bit of the wax paper shoved it here that way it can let it bleed out in this area if need be which I highly doubt it well because it’s in an area that should not collect much moisture but you never know now the last step here is these little zip ties these are header wrap or exhaust wrap type zip ties they are metal and designed specifically for heat I’m going to take those and put them next to these zip ties that are already in there and those are going to keep all this together if the adhesion from this aluminum foil type wrap comes apart it’ll it’ll keep it from letting the rest of it fall apart okay so you can see this is the splice here I got the connector for the evap right here that goes up to that hose that’s sitting up there and then right here I have the main fuel line connecting to it the quick connect if you trace this around you can see the section where I have the heat protection and that’s because you see the exhaust here now this exhaust is gonna go up and I’ll show you that as soon as I’m done showing you the rest of the line there’s the rubber hose I’m gonna zip tie this into place yet but I want to give you guys a visual of a before I put the exhaust on but here’s the line running all the way up and that is where I found the clean spot on the line for me to be able to reuse the old line and where I ended up flaring it so you can see the new line going all the way up and around and up there so there’s how that’s done now this is this is the line right here that I had to replace I was hoping that I could cut it back here because from the underside it looked fine but as soon as I pulled it down and started looking at the top I saw how rusty that was and that rust because the undercoating only sprayed on the bottom that rust ended up coming quite a ways and this is where all that protective plastic is and that plastic goes back all the way up to right here is the last one of those things for the plastic so I want right before that you can see it’s not very rusty here at all there’s just barely a smidge on the surface so that’s where I ended up putting the line now the exhaust here you see there’s quite a distance in this area there’s a lot of airflow that comes across this area to it so you really don’t have to worry about this getting very hot right up there is where the air is stagnant you get stuck and gets hot quite often and that’s why I had to heat shield that area and we come around the other side here and that’s where it goes down to so there you have it this line kit is complete and hopefully this helped teach you a few things about repairing rusty lines may be doing a flare hopefully helped you somehow someway like share subscribe and if you like what you see be sure to check out any of the links that come after I talk here and have a great day thanks for watching Chris performance repairs YouTube channel


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