How to Make Your Own Hydraulic Motorcycle Brake Line
- 1). Establish the path of the brake line from the master cylinder to the front or rear brake caliper. Select a path that allows the line to be secured to the frame of the motorcycle in one or more places.
- 2). Position a length of hydraulic brake line along the path you selected, starting from the master cylinder. Configure gentle bends in the line to allow an unrestricted flow of brake fluid. Mark the overall length of the line where it will terminate at the caliper using several tight wraps of masking tape.
- 3). Cut the brake line to length with cable cutters. Remove any wraps of masking tape. Secure the brake line in a bench vise with one end of the cable extending two inches to one side of the vise.
- 4). Apply a coat of solder flux around the end of the braided stainless steel. Tint one inch at the end of the stainless steel with 50-50 solder heated with a soldering gun. Fully tint the circumference of the braided steel. Allow the solder to cool completely.
- 5). Apply a generous solder bond over the tint, completely around the circumference of the braided steel. Immediately push the banjo fitting onto the solder bond by hand and twist the fitting 1/8 rotation to ensure a uniform bond. Allow the soldered attachment to cool completely.
- 6). Reposition the brake line in the bench vise with the opposite end extending two inches to one side of the vise. Apply flux and tint one inch at the end of the line as before. Allow the solder to cool.
- 7). Apply a solder bond over the tint, completely around the circumference of the braided steel. Immediately push the threaded fitting onto the heated solder bond by hand and twist the fitting 1/8-rotation to ensure a uniform bond. Allow the soldered attachment to cool completely.
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