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Originally Posted by Stretch
Wow Graham - I hope my next comment is taken as constructive criticism - but I think you are really over thinking this.
I know it is easier to give out advice when you are not emotionally involved with actually doing the job - I know some jobs are a bit daunting - but you have to crack on and start to do something other than over analysing it!
Give it a go. You've got a spare car if this one ends up with out any front brakes for a while.
My choice would be to try the fancy pliers if you can get them - that has the potential to be the easiest fix.
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It is the weekend, and the vice grip tool will only be here tomorrow. So I have time to overanalyze, because that tool IS my first option. But even if I am able to seperate that joint, the brass flare may get further damaged.
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If that doesn't work I'd set to pulling the hard line out of the car - then I'd replace it with what ever can be made locally for a reasonable amount of dosh.
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I have looked at that line quite a bit. A prebent line won't work - too complex a shape to fed through and clamp. So I need something flexible or that can be bent by hand. That's how I got to either braided flex or cupronickel.
Buying a flare tool, cutting off existing damaged end and installing a union and short extension may be easiest option. But I would need an inexpensive flare tool capable of flaring the existing steel line.
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Flexible lines from the master cylinder to the caliper is in my opinion a seriously expensive solution - they would have to be metal coated super duper high spec to stop any bulging during use - I am surprised that "racing people" consider that to be a good fix - I'd expect it to make the brakes feel really unresponsive; hard lines tend to flex less than the flexible ones...
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I am on my tablet and don't have the link, but I think a 60" DOT approved flex line costs about $35. Just don't know if they offer the end fittings needed. 60" would probably be enough to get from mc to passenger flex line bracket. It would be easy to install.
70" thermoplastic flex lines
http://www.amazon.com/Thermoplastic-Flexible-Hydraulic-Brake-37204-70/dp/B0079VH2CM
Stopflex braided s/s
http://www.classictube.com/products/stopflex-ss-braided-hose
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Graham
85 300D
,72 350SL, 98 E320, Outback 2.5