Making brake hoses - Russel fittings and hose

[mzerega]

All references in the following are regarding:

620131 - Russell PowerFlex Brake Hose End (straight -3 AN)
632500 - Russell PowerFlex Power Hose (-3 AN)

Anybody have a tried-and-true method for assembling Russel products? I've had two persistent problems while trying unsuccessfully to assemble their parts.


Problem #1
The first two pictures show an 0.011" interference fit between the hose and the socket -- too much to allow inserting the hose in the socket or "...sliding it back out of the way..."


This Russel Web page, it says "install the socket on the hose and slide it back out of the way." [this is not happening]
http://www.russellperformance.com/misc/tech/main.shtml

To fix this first problem, I sanded off the outer plastic layer on a 1-inch length of hose at the end (this doesn't seem like a good idea..but desperation makes us do these things). This allowed me to get the socket slid down far enough to get the brass 'olive sleeve' installed.

Problem #2
Once the olive sleeve is installed, the end of the hose expands such that it becomes impossible to slide the socket up far enough to get the threads to engage; the wire sleeve material overlapping the ferrule makes this impossible.

So, to fix this I carefully cut the wires near the narrowest part of the olive sleeve. This allowed me to slide the socket up to the threads.

Then, I put 160 lbs of compression force between the hose end and socket (hose end square on the concrete floor; standing on channel locks to push the socket down) while turning the threaded hose end with a wrench. The threads simply would not 'bite'

These parts don't appear compatible...or, perhaps special shop equipment is required (that isn't mentioned on Russel's Web site).

Anybody know how to properly assemble these lines at home?

[Hvy_Chevy]

try asking in general tech - probably more people using it there.

[cajunsuzukispider]

you sure it's the right hose? well, what are you trying to accomplish? the samurai hoses are short enough. and the sidekick passenger side hoses are plenty long enough. unless you need more than 20+" of brake hose. I built my rockcrawler with my hard brake lines run to the pivot point of the suspension. so now, I only need a little bit of travel in the brake hose to get 5' of wheel travel.(about).

[supazuk94]

they need to be cut clean and straight prior to pushing it on the the cone .. also you seem to have pushed the hose to far on it needs to allow the threaded sleeve to compress it as it is tightened

[talonxracer]

I recently built several brake lines and I had no issues sliding the nut over the outer vinyl coating. Are you sure you have -3 line and not -4?

[talonxracer]

I forgot to add that i trim the vinyl covering to the base of the "olive" fitting. I thought that was in the directions, but I just looked and it wasnt.