How to make your own hydraulic pipes
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  1. #1
    CitroŽn, what else? smiffy1071's Avatar
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    Default How to make your own hydraulic pipes

    There have been a number of threads recently about hydraulic pipes, and how expensive they are to have replaced.
    This need not be the case, if you make your own.
    Pliedes have a branch in Australia, and sell all the stuff you will need.

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    A roll of cupro-nickel pipe, about 20 metres is more than enough to do a whole car.

    A flairing tool, I found the hand held one best, as you can work directly on the car with it, where you can't with a bench one.

    An assortment of screw ends, seals, and maybe 2 or 3 double ended female couplings, depending on how many pipes you are going to renew.

    First, using a junior hacksaw, cut a piece of pipe to just over the length you need, and then gently file the end to get rid of sharp edges or burrs.

    Next, put a screw end on the pipe with the thread closest to the end of the pipe.

    Carefully line up the end of the pipe with the line in the lower half of the flare tool, and making sure the pipe doesn't move, screw the top half of the tool on very tightly.

    You can hold the tool in a vice, or with a 1 inch open end spanner. Insert the big flare screw, and turn with a spanner all the way in, till it bottoms out, then unscrew it completely.

    Undo the top half of the tool, and your flare is made, just put a seal on the end, bend to the right shape and the pipe is ready for use.

    The pics show me working with the most common 3.5mm size of pipe, but it's exactly the same for 4.5, or 6.5mm. (different size tools and screw ends/ seals, would be needed)

    john s
    Attached Thumbnails Attached Thumbnails How to make your own hydraulic pipes-pipe1.jpg   How to make your own hydraulic pipes-pipe2.jpg   How to make your own hydraulic pipes-pipe3.jpg   How to make your own hydraulic pipes-pipe4.jpg  
    2005 C5 2.0 VTR Hdi 138, 1986 Kawasaki GPz 750G2

  2. #2
    Fellow Frogger! ARCHRIVAL's Avatar
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    Default The Tool

    can anyone tell me whether this tool is available in australia and from where ? thanks
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  3. #3
    Real cars have hydraulics DoubleChevron's Avatar
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    Default

    I've got one here, but you would still need to order the line in !!

    seeya,
    Shane L.
    'Cit' homepage:
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    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/citro%EBn-forum/90325-best-project-car-you-have-ever-seen.html
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
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  4. #4
    Fellow Frogger! ARCHRIVAL's Avatar
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    Default Thanks Shane

    Shane your there and i'm here on the other side of the world . Did you get the apparatus locally? I mean in australia or did you have to import . I am a toolaholic so wouldn't mind one in my kit for future and present endevours . I assume all citroens ie hydraulic ones run the same pipes and fittings ?
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  5. #5
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by ARCHRIVAL
    Shane your there and i'm here on the other side of the world . Did you get the apparatus locally? I mean in australia or did you have to import . I am a toolaholic so wouldn't mind one in my kit for future and present endevours . I assume all citroens ie hydraulic ones run the same pipes and fittings ?
    I only have a 3.5mm line flarer. I got it with a trailer load of parts I bought. It's very small and I could chuck if in a postpack envelope to perth if you want to borrow it for a few weeks.

    There is Plaides in QLD, I'm sure they will sell you the tool. Didn't Smiffy say all the line and flaring tool was 80quid all up, so not bad at all (probably add another 20quid for postage).

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  6. #6
    Fellow Frogger! ARCHRIVAL's Avatar
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    Icon14

    thanks Shane I have sent an email to
    Pleiades Automotive Hydraulics (Australia)
    PO Box: 40
    Gayndah QLD 4625
    Phone: 07 4161 2512
    Fax: 07 4161 2512
    Email: [email protected]

    to see what they have got if they have all the stuff i might make up a kit
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  7. #7
    1000+ Posts edgedweller's Avatar
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    Default

    Any competent plumbing hardware store should have or be able to source these.

    ed ge

  8. #8
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by edgedweller
    Any competent plumbing hardware store should have or be able to source these.

    ed ge
    It's not a standard flare, it's a bubble about 5mm from the end of the line. There is bubble flares on cars now in the US (I've seen there bubble flare tools on ebay), however the line sizes are quite different .... Most likely NOT metric

    We need, 3.5, 4.5, and 6.5mm flaring tools.

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  9. #9
    Fellow Frogger! sdabel's Avatar
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    Icon10

    Shane, Just waiting for you to set up citroen hydraulic lines dot com!



    regards
    sean
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    1996 XM 2.1 TD Exclusive

  10. #10
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    Default

    Quote Originally Posted by DoubleChevron
    It's not a standard flare, it's a bubble about 5mm from the end of the line. There is bubble flares on cars now in the US (I've seen there bubble flare tools on ebay), however the line sizes are quite different .... Most likely NOT metric

    We need, 3.5, 4.5, and 6.5mm flaring tools.

    seeya,
    Shane L.
    I think you'll find that the larger pipe is 6.45mm, which just coincidentally is 1/4 inch. This is why when you get a rubber to metal pipe made (eg relocating DS pressure reg) you talk to them about 1/4 inch pipe at each end. Brains usually melt when you mention 6.45mm. I suppose 4.5 would equate to 1/6th (?) and 3.5 to 1/8th?

    My
    Craig K
    2009 C5 HDi Exclusive

  11. #11
    CitroŽn, what else? smiffy1071's Avatar
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    TOP TIP HERE!!

    If you are replacing a hydraulic line, and it looks corroded and yukky, ie, if you show it a spanner it will round off, Don't even try it!!!


    What I did on my car, is cut the pipe with a hacksaw right near the screw end, and using a deep SINGLE hexagon socket, not double, I was able to unscrew it without it rounding off.

    The new fittings that you get from pliedes are no longer the 8/9 mm fittings, but are machined from a 10 mm hexagon extrusion, that is then coated with Zinc, so it will last much better than standard citroen items.
    john s
    2005 C5 2.0 VTR Hdi 138, 1986 Kawasaki GPz 750G2

  12. #12
    Fellow Frogger! ARCHRIVAL's Avatar
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    Icon8 Kits not available in Australia

    The flare kits etc are not available in australia only from UK

    Pleiades in England can supply the cupro nickel pipe, pipe end fittings, line
    connectors seals and flaring tools for Citroen D, CX, BX etc.

    For full details please contact pleiades on: [email protected]

    Or by fax: 00 15 44 1487 832444 (phone: + 00 11 44 1487 831239)
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  13. #13
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by ARCHRIVAL
    The flare kits etc are not available in australia only from UK

    Pleiades in England can supply the cupro nickel pipe, pipe end fittings, line
    connectors seals and flaring tools for Citroen D, CX, BX etc.

    For full details please contact pleiades on: [email protected]

    Or by fax: 00 15 44 1487 832444 (phone: + 00 11 44 1487 831239)
    Did they give you a price ... It would be interesting to know how much some rolls of cupro nickel pipe and fitting are. There are some rounded fittings (or fitting that I'll have to destroy) on the rear of my CX in order to remove

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  14. #14
    Fellow Frogger! ARCHRIVAL's Avatar
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    Default not yet

    This was the response from the australian guys and the uk crowd have not responded yet
    will keep you posted
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  15. #15
    Fellow Frogger! ARCHRIVAL's Avatar
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    Icon5 Reply From Uk

    Type A (hand held) flaring tool costs £54. 3.5mm pipe is £1.40 per metre. Male fittings are 35p each. Rubber pipe seals are 15p each. Carriage is calculated on weight so I would need to know waht you require before quoting. All are stock items.
    WHAT DO YOU THINK I WOULD NEED FOR THE CX AND AS A BACK UP FOR BX AND FUTURE ENDEVOURS ?
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  16. #16
    Real cars have hydraulics DoubleChevron's Avatar
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    Have you thought about getting one of these:

    flaring tools

    It'll probably double the price of the flaring tool, however this will be with the fittings for all sizes of Citroen lines AND standard braking double flares for your other cars

    Smiffy would be the best to suggest lengths... However if you get one of the tools above I'd be tempted to get a few meters of 4.5 and 6.45mm line... you may never need it, but it'll be a life saver for the rust of us in Oz, 'cos we'll just email you with our piping needs

    seeya
    shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  17. #17
    Fellow Frogger! ARCHRIVAL's Avatar
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    Default Its a nice tool

    But at over $800 plus $200 for clampsets plus pipe and fittings plus postage and duty total ~$1600 I'd need to go into the business of making pipes and what is the demand in australia?
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  18. #18
    Real cars have hydraulics DoubleChevron's Avatar
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    It's bloody expensive, but not that bad:



    80quid ... flarer with standard clampsets for all your other vehicles...
    19quid ... 3.5mm clampset
    23quid ... 4.5mm clampset
    26quid ... 6.4mm clampset

    Total: 148quid ... or $343aud


    Plus lines, fittings, seal and postage...

    Yeah .... BLOODY EXPENSIVE .... If I win tattslotto .....

    seeya,
    Shane L.
    PS: You would only need two replace to lines on your car and it will have paid for itself.... Remembering 2nd hand Xantia lines out here are $200bux ++ each
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  19. #19
    Fellow Frogger! ARCHRIVAL's Avatar
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    Default umm

    shane don'nt those citroen clamps only fit the AFT the pricey one at 234 pounds ?
    BX 16v 89, I Renault Floride 62, Volvo P1800 68, Aston Martin DB6 68, Daimler 250V8 68, Jaguar XJC 76, Falcon Ute XL 62, Falcon Ute XY 4WD, Jeep Grand Larado 03, Mazda 6 Wagon 05, inter 483 tractor 86, makita cordless drill CX TURBO its dented D Special 1 62 ID192000 Xantia V6 2000 Cadillac STS stolen by the princess,KANGA 720DL LOADER

  20. #20
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by ARCHRIVAL
    shane don'nt those citroen clamps only fit the AFT the pricey one at 234 pounds ?
    If you look in the picture it shows the exact clampsets beside it that you mention I've sure a few years back I saw this flaring tool in a UK classic car magazine, that's why it won the awards... It does all the flares of all types.

    Still it's expensive.... Then again, price a quality standard flaring tool out here and I think you will in for a shock

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  21. #21
    CitroŽn, what else? smiffy1071's Avatar
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    Quote Originally Posted by ARCHRIVAL
    Type A (hand held) flaring tool costs £54. 3.5mm pipe is £1.40 per metre. Male fittings are 35p each. Rubber pipe seals are 15p each. Carriage is calculated on weight so I would need to know waht you require before quoting. All are stock items.
    WHAT DO YOU THINK I WOULD NEED FOR THE CX AND AS A BACK UP FOR BX AND FUTURE ENDEVOURS ?
    I'm only talking about the 3.5mm lines here. If you were to buy 50 of each item (screw ends, and seals) and perhaps 30metres of pipe, that should be enough to re-pipe the CX and the BX, and leave you lots of spare!
    I only bought 20 metres, and I recon I still have more than 5 metres left!

    I recommend when you order, that you buy 3 or 4 double ended female couplings.
    You might never use them, but, If you have a problem out on the road, with a burst line, and you can't replace the whole thing there and then, you can cut the hole away, and join the 2 broken ends together, to get you home!
    I call it a get out of jail free card!

    You could then after you have re-piped your cars, make it known to other members, that you are able to make pipes to order, to help offset the cost of the tool! After hearing that someone paid heaps of cash for a second hand line, I think you could earn some money! john s
    Last edited by smiffy1071; 6th October 2005 at 05:50 AM.
    2005 C5 2.0 VTR Hdi 138, 1986 Kawasaki GPz 750G2

  22. #22
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by smiffy1071
    I'm only talking about the 3.5mm lines here. If you were to buy 50 of each item (screw ends, and seals) and perhaps 30metres of pipe, that should be enough to re-pipe the CX and the BX, and leave you lots of spare!
    I only bought 20 metres, and I recon I still have more than 5 metres left!

    I recommend when you order, that you buy 3 or 4 double ended female couplings.
    You might never use them, but, If you have a problem out on the road, with a burst line, and you can't replace the whole thing there and then, you can cut the hole away, and join the 2 broken ends together, to get you home!
    I call it a get out of jail free card!

    You could then after you have re-piped your cars, make it known to other members, that you are able to make pipes to order, to help offset the cost of the tool! After hearing that someone paid heaps of cash for a second hand line, I think you could earn some money! john s
    He will only need enough for any lines that may need replacing on the CX (usually because you destroy them attempting to undo them). The cars out here simply don't rott there hydraulic lines .... ever ... My '63 ID19 still has all it's original hydraulic lines. Some of them are very coroded looking though. The tools is the sort of thing each car club needs. They would then lend it out for free, but only on leaving a $500deposit to make sure the bloody thing comes back ASAP.

    Most of our cars only need line replacements where the line has rubbed though/against something.

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

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