[RHClarke]

The past weekend session (Saturday) was spent measuring and making up new brake lines (a number of times...). If you are new at this aspect of restoration and want to make your own brake lines, the following is offered for your consideration:

If you have a small replacement job, use off the shelf lines already made up with the fittings.

If you are planning a number of brake line replacements, buy a coil of tubing and a box of fittings.

Make sure you have the right tools and know how to use them. Once you get them - practice!

The old saying "measure twice, cut once" means something. For those brake lines with all the bends- don't use the old lines as your guide - they may have been stretched over time, or forced together and you won't necessarily get the right length. Get a piece of stiff wire and use it to form a guide by bending it accordingly from the wheel cylinder to the division block - cut off excess.

Measure the guide length using a string and transfer to the new tubing.

Cut the tubing and file down the outside lips. Gently ream the inside lips (blow out any shavings).

Use a bending tool (pliers type or spring tube) to make your initial bends (carefully).

Take the newly bent tubing to the truck and fit it. True up the bends (carefully) using the spring tube (remember bend a little at a time).

There are plenty of online resouces that can walk you thru the bending steps, but they all assume you have some experience doing this, so "make haste slowly" (it saves on rebending a second or third set of lines - Bob is still chuckling...).

Instead of trying to bend up the small pig tail like line (8 inches of curling hell that links the HUP master cylinder to the line that runs the rail etc...), replace it with a rubber brake hose. It will be out of sight anyway...

Once assembled - pressure test everything - twice. Your life will depend on your brakes! If in doubt - get a pro to make up your lines.