How to Fix Leaky Brake Line Fittings

If your brake line is leaking where the flare joins the fitting it is important to address the issue immediately and with a legitimate solution.

I was fed up with the unreliable, “band-aid” fixes out there when I was repairing a leaky brake line on my Packard Coupe. As a result, I created the Surseat Flare Lapping Tool and Fitting Fixer.

Why Brake Lines Leak at the Flare

Brake lines will leak at the flare when there is a poor connection with the seat of the fitting. This type of leak is commonly known as a weep. It is the result of a tiny imperfection in the flare that occurs while flaring the tube. No matter what flaring tool I used, I never got a clean, concentric finish that enabled the flare to seat with the fitting. Furthermore, it didn’t matter if I was using steel lines with a 45° double flare or stainless steel lines with a 37° single flare.

Why Brake Lines Leak at the Fitting

Most of the time the cause of a leaky flare fitting connection has to do with the flare, but there could be a problem with the fitting. Fittings can get damaged by over tightening them with an imperfect flare, by dropping them, or from some other accident where you end up with a ding. A damaged fitting can be very problematic, especially when it’s built into a radiator or welded into a tank.

How to Seal Flare Fitting Connections

Lapping is a tried and true practice that goes back 100 years. Even with the best equipment, mechanics always lapped engine valves to ensure they wouldn’t leak. It occurred to me that lapping the flare on the brake line could get the tube to seat with the fitting.  I decided to apply this principle to flared tubing, and it fixed the leak I was getting in my Packard.

Here’s how to lap flared tubing:

1. Unscrew the brake line from the fitting.
2. Clamp the appropriate-sized collet around the line.
3. Connect it to the Surseat lapping tool.
4. Spray some lubricant to the lapping head before using it.
5. Rotate the lapping head back and forth about 6-10 times.
6. Clean and inspect the flare. There should be a smooth, concentric finish. If not, repeat step #5.
7. Remove the brake line from the Surseat and reconnect it to the fitting.
8. Bleed the brakes and check the seal.

► Click here to shop Surseat lapping tools.

How to resurface fittings:

1. Screw the fitting into the Fitting Fixer guide.
2. Connect the lapping head to a drill or tap handle.
3. Spray some lubricant into the cavity of the lapping head.
4. Insert the lapping head into the guide and over the fitting.
5. Spin the lapping head on the fitting, releasing every 2-3 seconds to prevent clogging.
6. After about 5-6 passes, remove the fitting and inspect the surface. Repeat step # 5 if necessary.

► Click here to shop Fitting Fixer tools.

How to Check for a Leak Where the Flare Joins the Fitting

If you have your brake or fuel line out of your vehicle, there’s an easy way to check to see if there’s a leak at the fitting.

First, plug the end of the tube that you are checking by screwing in a cap flared tube nut or anything similar that will seal off that end of the tube. You can also purchase Earl’s Performance Pressure Test Kits if you don’t have anything that will work.

Next, submerge the line in water and run air through the opposite end of the tube. If bubbles appear at the fitting, the seal is no good. Repeat the lapping process until you get no bubbles.

Real-World Examples

Here are some testimonials from people that have used the Surseat lapping tool to seal their flare fitting connections:

“I have been double flaring brake lines for street rods for 30 years with great success. My latest project, a 32 Ford Roadster, had 6 fittings that I could not get to seal. After continuously trying to tighten the fittings, hoping that the joint would seal, I couldn’t eliminate the weep in the brake system. I remember seeing this tool at the Street Rods Nationals and decided to order one to see if it would solve my problems. I disassembled the entire brake system and lapped every flare with the Koul Tool P45. Then I reassembled the brake system and didn’t have a single issue. From now on, I will lap every fitting I make just to make sure I get a proper seal on my brake fittings. The tool is easy to use and certainly performs.”

– Bill Kantos

“I use the Surseat flare lapping tool when building the hard line brake system for my 410 sprint cars. My flaring tool is good, but even when using the best of tools, sometimes the flare seat just doesn’t seal perfectly without excessive tightening of brake connection. Your Surseat lapping tool results in a perfect seal without excessive tightening. The tool provides a lapping action on the formed flare. You can see the lapping marks around the flare which indicates that you will have a perfect seal upon assembly. Use of the tool takes only minutes and prevents having to replace lines due to leaks.”

– John Shewbrooks Racing

More About the Surseat

The Surseat flare lapping tools have a precision, diamond-dust coated lapping head that will hone tubing flares to enable them to seat with the fitting. They come in three different models:

• The Surseat P-51 has interchangeable 37° and 45° lapping cones and will do 3/16″ to 1/2″ inch tubing. This is your “complete kit” for brake and fuel lines.
• Surseat “Minis” are designed specifically for brake lines. The smaller size and rectangular shape of the P-45 and P-37 make it easier to work in tight spaces inside the car. Each model has a single 45° or 37° lapping head and collets to secure 3/16″ or 1/4″ brake lines.