Note: This method is used for copper pipes with a diameter of 4.7 mm.
This method is not applicable:
- for hybrid pipelines (rigid tube + hose);
- for pipelines with diameters of 6 mm and 8 mm.
Using a pipe cutter, cut the tubing to the recommended length.
Install nuts or bolts onto the pipe before forming rivets.
Manufacturing of rivets
To make a rivet, place the rivet press in a vice.
Place the pipeline in the rivet press.
Adjust the length of the pipe to achieve the desired shape.
Tighten the press tip to the required torque (40 Nm).
Visually check:
- uniformity of rivet diameters;
- centering of rivets relative to the pipeline axis.
Visually check that the internal diameter of the pipeline has not become oval.
Use a caliper to ensure that the back panel diameter is not oval.
Normalize the diameter if (X ₁) = (X ₂).
Preparing the pipeline before bending
Blow out the pipeline in both directions using an air-powered spray gun.
Install plugs on the bolts or nuts at the ends of the pipe.
Install the standard pipeline on a flat support plate, the length of which is equal to the length of the pipeline.
Measure the dimensions (XZ) in mm of all bends, between the "centers of the radii of all bends" (1) of the old pipeline.
Note: To avoid weakening the pipe, either bend it once or bend it gradually increasing the bend (i.e. reducing the bending radius). Do not install rigid tubing on a vehicle that may have been bent and then straightened back out to achieve the correct bend radius.
Note: During the bending operation, it is necessary to slightly exceed the required angle to compensate for the elasticity of the material.
Give the pipeline the required shape using a bending device, one bend after another, maintaining the original shape of the pipeline.
Bending test
Check the deviation from the circle shape of the outer diameter at the center of the bending radius (2) using a caliper (the deviation of the outer diameter from the circle shape is normal if it is flattened by less than 10%):
- nominal pipeline diameter: 4.75 mm;
- minimum diameter after bending: 4.30 mm.
Note: When installing a rigid brake line:
- keep to the original layout as much as possible;
- adjust the pipeline routing by hand when installing it into the clamps.
Caution: Contact points between the rigid brake line and surrounding elements may cause damage to the line. To avoid this contact, manually adjust the line routing.
Tighten the brake pipe mounting bolts to the specified torque of 8 Nm.
Tighten the fittings under the body bottom to the required torque (external/internal thread) 6 Nm.