Custom and Prebent Brake Line Basics - 4-Wheel & Off-Road Magazine

Kevin McNulty Former Editor, Mud Life

Horsepower and torque are usually our first thoughts when building, modifying, or restoring a trail rig. Braking usually takes a backseat to other performance components. We've run across a number of super-cool trail rigs, but have time and time again noticed the cobbled-together and barely working brake system. Brakes are without a doubt the most important part of any build due, a fact that has hit home if you've ever had your 4x4 teetering on the brink of destruction at the edge of a shelf road or cliff!

131 1105 Custom And Prebent Brake Line Basics jeep Front Shot Photo 30692942

Over time the brake systems of our 4x4s degrade and rust and become contaminated, leading to major safety concerns. We have had brakes fail and felt the wrong peddle hit the metal a number of times. Careful attention and planning should always be at the forefront of any build for the safety of yourself and your passengers.

131 1105 Custom And Prebent Brake Line Basics suspension Travel And Brake Line Photo 36166395 Good brakes are critical to the safety of any vehicle. When you're modifying a trail rig with a lift, take into account the suspension travel when determining brake line length and placement. Make sure the brake lines don't rub against the tires and that they cannot become bound and torn off in the springs or shocks.

Classic Tube and ABS Power Brake manufacturer quality brake system components for complete replacement systems and custom applications. Both companies can provide the proper components for vehicle modifications like axle swaps, suspension lifts, and complete restorations.

131 1105 Custom And Prebent Brake Line Basics classic Tube Brake Line Kit Photo 36166398 Classic Tube offer complete prebent replacement brake line systems for just about any vehicle. The lines can be ordered in O.E. steel, aluminum, or 304 Grade stainless steel like this system. Some of the prebent lines also feature a gravel or armor guard, which protect them from punctures and wear from chaffing against the body or frame. Stopflex flexible brake lines are designed for strength and no expansion, which gives the system firm braking. The Stopflex lines can be ordered in any length. PhotosView Slideshow The 9-inch GM-style Corvette dual master cylinder booster system is a quality unit that's not remanufactured, which will give peace of mind when you're in precarious positions on the trail. ABS Power Brake matched the master/booster combo to our build, and the unit will offer enough braking power for the Dana 60 axles fitted with disc brakes front and rear. Using the right proportioning valve when converting from drum to disc brakes is very important as it will allow the vehicle to brake safely. A matched proportioning valve helps distribute the braking power properly (reducing rear pressure) in the system from front to rear brakes. Bulk brake line and the tools to bend and flare the tubing are available from Classic Tube, making a custom and intricate job easy. Improperly bending brake line leads to kinks and weakened bends that will restrict brake fluid flow. The few extra bucks the line bender costs are well worth it.
The overall size of the GM-style master booster system fits our Scratch-Built Scrambler project nicely and cleared the underside of the hood. We had to redrill the mounting holes, and the unit's adjustable master cylinder peddle rod helped get the brake pedal in a comfortable position inside the cab of the Jeep. The guys at T&J Performance Center in Orange, California, let us use their facility for the installation and helped mount some of the brake line components. Their technician welded a bracket to mount the proportioning valve above the framerail and out of harm's way. Not only is the position of the valve away from the exhaust headers, but it keeps the brake lines high on the inside of the frame so they are not crushed by rocks or ripped off by logs or branches. A typical rear axle brake line setup places the line junction block in the center of the axle and runs the lines up high from left to right. Routing the lines this way keeps them safe in harsh conditions.