Step one. Bought the van.
Hello Everybody, First post. I camp a lot in tents but after spending three days straight in a tent in the rain at Dolly Sods I swore I'd make a change. Here it is. Bought it Wednesday. Dro...
Forum Discussion
Undervan Storage Box:
Correction: In my previous posting I wrote about replacing the rear brake line. I made a mistake that needs to be corrected. When I flared the end of the brake line I used a single flare kit. This is wrong. I should have used a Double flare kit.
My thanks goes out to "Boomer2" at the Ford-trucks.com forum for bringing this to my attention.
Here is a picture of my single flare kit next to a double flare kit. The double flare kit was kindly lent to me by the owner of my local repair garage. (Thanks Gary!)
The main difference between the two kits is the double flare kit has a several round "adapters".
Here's how I used it. Cut the brake line like before.
Use the reamer on the inside of the brake line.
Rub the end against some fine sandpaper to smooth it out.
Do the same to the edge. Be sure it's clean when you're done.
Find the adapter that matches the 3/16" brake line that I'm using.
The divot on the end of the adapter will be placed against the tip of the flaring cone.
This is the other side of the adapter. Notice the small curve next to where the stem joins the adapter. This is what will form the first flare.
Place the brake line into the corresponding hole in the flaring bar.
Slide the brake line through the flaring bar till it extends a distance equal to the thickness of the adapter at it's first "step".
Use the cross-bar on the flaring tool to tighten down on the thumb screws on the flaring bar. If you try to just finger tighten it the brake line will slip out when the flaring tool is used.
Place the stem end of the adapter into the brake line.
Put the flaring tool on the flaring bar centered over the adapter. It's real important to keep the adapter and the flaring cone centered as they are being used.
Tighten down on the flaring tool until the adapter is flush against the flaring bar.
Remove the flaring tool and adapter. This is how the end of the brake line appears after using the adapter. This is the first flare.
Next center the flaring cone over the brake line.
Tighten down the flaring tool until it stops.
Here is how it appears after the tool has been removed. This is the double flare.
From what I've read the purpose of the double flare is to strengthen the brake line at it's seam. In the picture below look at the 12 o'clock position on the inside of the brake line. The visible line is the seam where the metal was joined to create the brake line. A single flared brake line is more likely to split along this seam. The double flair is actually folding over the end of the brake line which should reinforce the seam.
I practiced with the double flare kit on a new section of brake line before fixing the van.
While practicing I found that unless the flaring tool is well centered the flared end can be lopsided.
To fix what I'd previously done on the van I'd have to remove the single flare on the end of the brake line where it connects to the rear passenger wheel. After cutting off the single flare the brake line would no longer reach so I'll use a 3/16" union to extend it.
Since the fitting that secures the brake line to the brake cylinder was so chewed up I decided to replace it. The local auto parts store said the fitting was a 1/4" npt. They didn't had a direct replacement, even though the counter jockey told me they used to carry them, so I'm using a 3/16" to 1/4" adapter. In the below picture you can see both the old fitting and a union.
Here is the new adapter installed on the wheel cylinder along with the brake line and fitting.
This is the union.
After messing with the brake lines I had to flush them again. To flush I use a piece of vacuum hose attached to the bleeder valve.
Use clear tubing from the vacuum line to the waste container. Need the clear tubing so I can see if there are any air bubbles in the expelled brake fluid.
Sunset from under the van.
Not pictured: My neighbor who's working the brake pedal. (Thanks John!).
continued -
Correction: In my previous posting I wrote about replacing the rear brake line. I made a mistake that needs to be corrected. When I flared the end of the brake line I used a single flare kit. This is wrong. I should have used a Double flare kit.
My thanks goes out to "Boomer2" at the Ford-trucks.com forum for bringing this to my attention.
Here is a picture of my single flare kit next to a double flare kit. The double flare kit was kindly lent to me by the owner of my local repair garage. (Thanks Gary!)
The main difference between the two kits is the double flare kit has a several round "adapters".
Here's how I used it. Cut the brake line like before.
Use the reamer on the inside of the brake line.
Rub the end against some fine sandpaper to smooth it out.
Do the same to the edge. Be sure it's clean when you're done.
Find the adapter that matches the 3/16" brake line that I'm using.
The divot on the end of the adapter will be placed against the tip of the flaring cone.
This is the other side of the adapter. Notice the small curve next to where the stem joins the adapter. This is what will form the first flare.
Place the brake line into the corresponding hole in the flaring bar.
Slide the brake line through the flaring bar till it extends a distance equal to the thickness of the adapter at it's first "step".
Use the cross-bar on the flaring tool to tighten down on the thumb screws on the flaring bar. If you try to just finger tighten it the brake line will slip out when the flaring tool is used.
Place the stem end of the adapter into the brake line.
Put the flaring tool on the flaring bar centered over the adapter. It's real important to keep the adapter and the flaring cone centered as they are being used.
Tighten down on the flaring tool until the adapter is flush against the flaring bar.
Remove the flaring tool and adapter. This is how the end of the brake line appears after using the adapter. This is the first flare.
Next center the flaring cone over the brake line.
Tighten down the flaring tool until it stops.
Here is how it appears after the tool has been removed. This is the double flare.
From what I've read the purpose of the double flare is to strengthen the brake line at it's seam. In the picture below look at the 12 o'clock position on the inside of the brake line. The visible line is the seam where the metal was joined to create the brake line. A single flared brake line is more likely to split along this seam. The double flair is actually folding over the end of the brake line which should reinforce the seam.
I practiced with the double flare kit on a new section of brake line before fixing the van.
While practicing I found that unless the flaring tool is well centered the flared end can be lopsided.
To fix what I'd previously done on the van I'd have to remove the single flare on the end of the brake line where it connects to the rear passenger wheel. After cutting off the single flare the brake line would no longer reach so I'll use a 3/16" union to extend it.
Since the fitting that secures the brake line to the brake cylinder was so chewed up I decided to replace it. The local auto parts store said the fitting was a 1/4" npt. They didn't had a direct replacement, even though the counter jockey told me they used to carry them, so I'm using a 3/16" to 1/4" adapter. In the below picture you can see both the old fitting and a union.
Here is the new adapter installed on the wheel cylinder along with the brake line and fitting.
This is the union.
After messing with the brake lines I had to flush them again. To flush I use a piece of vacuum hose attached to the bleeder valve.
Use clear tubing from the vacuum line to the waste container. Need the clear tubing so I can see if there are any air bubbles in the expelled brake fluid.
Sunset from under the van.
Not pictured: My neighbor who's working the brake pedal. (Thanks John!).
continued -
