DIY on-car flaring tool

This is the Forum for all your Citroen Technical Questions, Problems or Advice.

Moderator: RichardW

User avatar
CitroenCrazy
Donor 2020
Posts: 124
Joined: 20 Mar 2005, 19:17
x 41

DIY on-car flaring tool

Post by CitroenCrazy »

My Xantia disgraced itself by bursting one of the high pressure pipes that runs from front to back.
Access is pretty terrible at both ends, so I decided the only way I was going to get the car mobile again was to replace just the rusty section. In theory, this should be straightforward; cut the affected section out, flare the pipe on each side and use a pair of in-line connectors to splice in a new section.

In practice, this gave me a problem because I only have a bench-mounted flaring tool, which I bought from Pleiades about 25 years ago.
I know people have managed to use this type of tool on the car, but being cam-operated, it's really not designed for that type of application.
01_source.JPG
I was quite prepared to buy a new flaring tool, intended for use on the vehicle. BeePro in Germany make a very nice example, but with shipping to the UK, it's over £350.
I couldn't find anything else at a price I was prepared to pay, so I decided to try making my own, using the punches and dies from the Pleiades tool I already have.

Hopefully this will inspire someone else to do the same and also spawn suggestions for improvement.


I found a nice chunky piece of U channel in my reclaimed metal stock, so that became the body, and I made the other parts to fit around that.
02_body.JPG

The new tool had to be screw-operated, and flaring steel pipe needs quite a bit of force, so I threaded a piece of bar M20 x 1.0 pitch
03_threading.JPG

This is the kit of parts about 2/3 of the way through the build
04_parts.JPG

This is the main part of the tool, just about complete. (The punch and dies in the picture are DIN style, not Citroen)
05_finished.JPG

The first attempt at flaring a piece of steel pipe was a bit disappointing
06_first flare.JPG

I'd diverged from my original plan a little, deciding to use the later style of screw-in punches, as this would make it easier to incorporate an extraction mechanism.
What I didn't realise until late in the process is that the new punch is narrower than the original one and a very loose fit in the dies, hence the lop-sided flare.
(Original Pleiades punch on the left, new style on the right)
07_problem definition.JPG

So, I made a sleeve to bring the diameter back to the same as the original punch
08_turning a sleeve.JPG


This is a close up of the punch holder, showing how it fits over the compression screw. The idea is that the punch is pulled back as the screw is unwound.
09_punch extraction.JPG

The completed tool, with a quick coat of spray paint
10_painted + complete.JPG

In use today
11_in use.JPG

The result
12_on-car flare.JPG

At the risk of sounding smug, I was pretty chuffed with the result :-)
Last edited by CitroenCrazy on 27 Sep 2020, 21:41, edited 2 times in total.

User avatar
bobins
Donor 2020
Posts: 3395
Joined: 05 Jul 2012, 18:07
x 982

Re: DIY on-car flaring tool

Post by bobins »

Appearing on eBay soon ? :lol:

User avatar
Paul-R
Donor 2020
Posts: 4153
Joined: 07 May 2009, 16:24
x 426

Re: DIY on-car flaring tool

Post by Paul-R »

CitroenCrazy wrote:
27 Sep 2020, 19:29
At the risk of sounding smug, I was pretty chuffed with the result
Frankly, you've every right to feel smug. That's a fabulous bit of kit you've created.

User avatar
NewcastleFalcon
Posts: 12594
Joined: 25 Feb 2009, 11:40
x 1171

Re: DIY on-car flaring tool

Post by NewcastleFalcon »

Top work CitroenCrazy well done. I have put a link to your post on the Toolbag Tales, Homemade and improvised tools thread

REgards Neil

User avatar
mickthemaverick
Donor 2019
Posts: 4008
Joined: 11 May 2019, 17:56
x 1185

Re: DIY on-car flaring tool

Post by mickthemaverick »

Brilliant piece of work. :clap: Now I know where to come if I get rusty pipes!! :-D

User avatar
white exec
Moderating Team
Posts: 6240
Joined: 21 Dec 2015, 13:46
x 1051

Re: DIY on-car flaring tool

Post by white exec »

Superb work. I feel sure I'll be needing to make something like that at some point.

User avatar
CitroenCrazy
Donor 2020
Posts: 124
Joined: 20 Mar 2005, 19:17
x 41

Re: DIY on-car flaring tool

Post by CitroenCrazy »

Ahhh, thanks guys. Blushes.........

Available on loan to anyone local.

Gibbo2286
Donor 2020
Posts: 4700
Joined: 08 Jun 2011, 18:04
x 833

Re: DIY on-car flaring tool

Post by Gibbo2286 »

The Chinese will have copies on sale soon.

Online
Hell Razor5543
NOT Alistair or Simon
Posts: 10713
Joined: 01 Apr 2012, 09:47
x 1053

Re: DIY on-car flaring tool

Post by Hell Razor5543 »

Gibbo2286 wrote:
28 Sep 2020, 09:10
The Chinese will have copies on sale soon.
You mean they haven't already?

User avatar
CitroJim
A very naughty boy
Posts: 42146
Joined: 30 Apr 2005, 23:33
x 1238

Re: DIY on-car flaring tool

Post by CitroJim »

Absolutely first class :D Most excellent :D