I can't believe that I have to post about this... but my car's been held up for some time because I just cannot get a decent double flare.
I'd spend an hour almost making an exact repro of the rear axle to caliper's solid line, then practice a double flare and then do it to the new line, only to have it come out shittty. Cut it off, and re-do it and it comes out worse.... over and over to the point that the line becomes to short to use. It's such a simple job that is kicking my azz.
The flare ends up squooshing over to one side some, mostly because of the 1st step, but the 2nd step really makes it bad.
I have a BluePoint double flaring kit, and when that wasn't working well, borrowed a co-worker's MAC flaring kit. His 3/16" die looks a lot more shallow than mine and won't bottom out... anyways, this is the setup:
Using normal steel 3/16" tubing from NAPA. BluePoint or MAC flaring kit. I am cutting the tube squarely with a decent tubing cutter, and lightly filing the leftover burr flush to the actual cut end, using the "reamer" of sorts to remove the inside burr, and then putting a slight chamfer on the od of the end, as well. And yes, I am using the 1st step of the forming die on both sets to get the proper height.
I've tried a light film of oil on the die and the 45 double flaring part.... helps maybe a wee bit. Made sure the tubing is straight so it's nice and square in the two die halves. Tightened the halves up real good, and extra 1/2 turn with the handle to make sure the tubing doesn't slip when forming.
I even looked on youtube for some hints and saw one guy inverts the tubing flush to the backside at 1st, and takes a file and files it flush to ensure it's square as this is totally important, but my bluepoint die halves don't sit totally flush to each other like the MAC does, and I don't want to marr up his tool.
WTF am I doing wrong?
I do think that after I get a dismal flare and I cut it off, that 1" section from the end shouldn't be used as it might be work hardended. I heard that you should actually use a special saw as the tubing cutter work hardens the tube and makes it difficult to flare squarely.
Do you think it's the NAPA quality steel tubing giving me troubles?