Hard Brake Line Repair

[Toran]

Hello Good People,

While trying to remove some extremely rusted brake lines the nut became stripped. So stripped that it is now round and still stuck.

Q: Can the hardline be cut at the pink mark and fitted with something that can be had at an AutoZone, Advance Auto, Harbor Freight?

Break it down with some clear descriptive feedback please.

T.I.A.

[Slam]

Yes, it can be cut there but with a caveat. You'll need a proper flaring tool and you'll have to make sure there's enough 'slack' in the hardline so you can make it reach the fitting without bending or kinking. And you'll need a new flare nut, of course.

[Toran]

What's a caveat?
So I need to get a flare tool and a flare nut?

[Rasta Monsta]

FWIW, a flare wrench should be always used on these fittings.

[Slam]

A caveat is what you cut 944 brake lines with...

Kidding. Caveat is a warning, a hitch, a string attached. (Legalese, Rasta?)

[Toran]

Your right gotta keep your humor even while the car is on jack stands!
:-)

[HondaDustR]

A big pair of vice grip pliers saved me in these situations. Heat will help alot, too, gently, though. You have to kind of play chicken with the nut as to how hard you can get away with clamping on it with the pliers without risk of terminal deformation.

Also, someone here swears by a 50/50 mix of acetone and ATF as a penetrating oil.

[rmcdonnell]

Hi Toran,
you can go back to an earlier stage and check you can undo the brake line nut before this stripped one, and the hose from the caliper, see if you can shift them just a crack. If you can...

then you can cut the pipe off, at your pink line, and get a socket on it. Once you have the bits out, because they have given up, or sheared, you can get a new bit of copper pipe or cunifer made up for not very much, or as others suggest, buy your own flaring tools and make some new bits yourself.

But I really wouldn't try to salvage your rusty steel brake line. It's easy and cheap to replace with copper or cunifer, especially the short runs under the wheel arches.

Cheers
Rissole

[Toran]

Thanks for the feedback everyone!

Yes I have replacement SS brake lines so the ones on there now just need to go.

Picked up a replacement hard line from PepBoys for the passenger side.
Does anyone know how much longer the driver side hard line is?

[89-944NA]

Also, if you do attempt the cut and repair route, make DARN SURE you get all the itty bitty shards of metal out of the line before you repair it...in other words, flush the line by disconnecting it at the next fitting (CAREFULLY..no strip here) upstream and then flush.

BTW, you can get a good CAVEAT in the craftsman line at sears, with a lifetime guarentee...and they are cheap.

You can find them next to the left-handed smoke shifters, bacon stretchers, toothpick sharpeners and that always in high demand 100 yards of flight line (yeah, they got jet blast and prop wash too)

[HondaDustR]

Yeah, use one of those plumber's tubing cutters. HVAC techs use them because they make a clean cut with no shavings or particles. I have seen brake line stock at NAPA that can be custom bent as needed.

[Toran]

Thanks!

Any insight on the driver side length?

T.I.A.

[89-944NA]

about that () long? I know, I can be a wiseass at times.

[rmcdonnell]

I think it is probably about three inches shorter on a LHD drivers side, if your passenger side has ABS, but you need to measure your own set up; assuming that Porsche run the hard brakelines in the same places on both left and RHD cars, ie America and ROW/Euro layout might be the same.

Essentially my RHD drivers side ABS lines were about 3 inches longer than my passenger side when straightened out.

Measure twice, cut once
cheers
Rissole

[Toran]

THANK YOU EVERYONE!

All the support and feedback was very helpful and the problem was resolved.
Ended up getting the brake lines from PepBoys.

Now trying to turn those rusty caliper valves for bleeding is another story...

[89-944NA]

before you do this, do yourself a favor and go purchase the proper size flare nut wrench (it will surround all but one side of the nipple) or use a box wrench, do not use a deep socket and ratchet, as you can quite possibly exert to much torque and snap the nipple, an open end wrench will just strip the sides like you did on the fitting.

[Toran]

89-944NA, do you off hand what size flare wrench is needed?

[89-944NA]

I am not sure what size it will be on your 86NA, I know on my turbo S it is an 11mm, and if I remember correctly, the nipples are smaller on the NA's. If nobody has posted the information for you by sunday morning, I will check on a friends NA for you.

[Rasta Monsta]

8 or 9, I think. . .but a set would be worthwhile.

[HondaDustR]

Yeah, 8mm sounds right for the front. The rear is smaller on mine, 7mm I think. The line flare nuts are 11mm IIRC.