With all the discussion on this thread, I thought I'd share how I've made my flares and solicit positive/negative feedback.
Please, let's not debate the type of material used, rather the technique of making the flare.
So without further adieu, here we go.
1- Rolling the coil out on the table produces a relatively straight line.
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2- Cut the tube with a vibrating tool like this, rotary grinder, hack saw, or similar. Do not use a plumber's cutter! It crushes the tube, leaves a bad ridge, and won't work for flaring.
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3- Put the tube into the bending tool. Carefull not to scratch the tube...some of the edges on the tool will do it.
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4- This bender can only do a maximum of 90 +/- degrees. Some can do more...up to 180* I think.
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5- Now that I have the tube bent in the appropriate shape. Let's address the ugly ends. BTW, no need to make the ends pretty first only to mis-bend and have to start all over.
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6- Important that the end is square...a light touch on this sander does the job.
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7- Lightly clean up the scratch marks from the sanding on the scotch-brite wheel.
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8- Just a very light touch on the scotchbrite wheel to remove the side burr. Don't take away any material, just the burr.
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9- This one technique to address the inner burr. Don't go too much...a light touch is key here.
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10- Here is another technique. I find I like this better on the 3/8" tubing.
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Continued on next page...
Please, let's not debate the type of material used, rather the technique of making the flare.
So without further adieu, here we go.
1- Rolling the coil out on the table produces a relatively straight line.
------->
![1.jpg](/community/proxy.php?image=https%3A%2F%2Flh3.googleusercontent.com%2F-VxCgLQ0PNFM%2FTq4A76WRHjI%2FAAAAAAAAAvs%2FHdNFXkDm1Uc%2Fs800%2F1.jpg&hash=dd7e0803c9febc9c70b7ff592f78f1a6)
2- Cut the tube with a vibrating tool like this, rotary grinder, hack saw, or similar. Do not use a plumber's cutter! It crushes the tube, leaves a bad ridge, and won't work for flaring.
------->
![2.jpg](/community/proxy.php?image=https%3A%2F%2Flh5.googleusercontent.com%2F-U5YiV8GJfiE%2FTq4A7ugYJiI%2FAAAAAAAAAvc%2FCtEVlSY5yF8%2Fs800%2F2.jpg&hash=19652a36cf95f46ce074c75b23ba7d9f)
3- Put the tube into the bending tool. Carefull not to scratch the tube...some of the edges on the tool will do it.
------->
![3.jpg](/community/proxy.php?image=https%3A%2F%2Flh6.googleusercontent.com%2F-ERsJH_DCG2g%2FTq4A7hqFtgI%2FAAAAAAAAAvg%2F6CL7l7tll-s%2Fs800%2F3.jpg&hash=50856133adcdbd437adecd8d7a30970a)
4- This bender can only do a maximum of 90 +/- degrees. Some can do more...up to 180* I think.
------->
![4.jpg](/community/proxy.php?image=https%3A%2F%2Flh4.googleusercontent.com%2F-Q2xN1w51E1Q%2FTq4A7R-YjPI%2FAAAAAAAAAvM%2FqG18ZYSmEfc%2Fs800%2F4.jpg&hash=9cdf47ca7f06c2b462277c71cc0cd6f5)
5- Now that I have the tube bent in the appropriate shape. Let's address the ugly ends. BTW, no need to make the ends pretty first only to mis-bend and have to start all over.
------->
![6.jpg](/community/proxy.php?image=https%3A%2F%2Flh5.googleusercontent.com%2F-fOwmXl14L3s%2FTq4A7SDlmjI%2FAAAAAAAAAvQ%2FK6p25PusUj8%2Fs800%2F6.jpg&hash=9e65080f01f882d895ac795cda11935f)
6- Important that the end is square...a light touch on this sander does the job.
------->
![7.jpg](/community/proxy.php?image=https%3A%2F%2Flh5.googleusercontent.com%2F-aWZl2gv_CTw%2FTq4A7KISJ-I%2FAAAAAAAAAu8%2FZ3RhAFoGcH8%2Fs800%2F7.jpg&hash=860039ae27a574cf65ab0f084e68d88a)
7- Lightly clean up the scratch marks from the sanding on the scotch-brite wheel.
------->
![9.jpg](/community/proxy.php?image=https%3A%2F%2Flh4.googleusercontent.com%2F-1Z_KEK_-InU%2FTq4A65zaGTI%2FAAAAAAAAAus%2FhRnMSjHAfCE%2Fs800%2F9.jpg&hash=8d75f30011c77cae1bd63e13183e99d9)
8- Just a very light touch on the scotchbrite wheel to remove the side burr. Don't take away any material, just the burr.
------->
![8.jpg](/community/proxy.php?image=https%3A%2F%2Flh6.googleusercontent.com%2F-WgjG0AiTBI8%2FTq4A65RQhZI%2FAAAAAAAAAuw%2FIxuZrzvlA4w%2Fs800%2F8.jpg&hash=cec06baeb4ba4844de3ad7ecab5469df)
9- This one technique to address the inner burr. Don't go too much...a light touch is key here.
------->
![10.jpg](/community/proxy.php?image=https%3A%2F%2Flh5.googleusercontent.com%2F-b37adBzHX7A%2FTq4A6nssl8I%2FAAAAAAAAAvA%2FrRptfffu1tE%2Fs800%2F10.jpg&hash=f2274b5323cfd13a8fd9fee0f82b127a)
10- Here is another technique. I find I like this better on the 3/8" tubing.
------->
![11.jpg](/community/proxy.php?image=https%3A%2F%2Flh4.googleusercontent.com%2F-grE6HNylm5o%2FTq4A6sCLsHI%2FAAAAAAAAAug%2FP63Vq_fGwLw%2Fs800%2F11.jpg&hash=e823789fae95e1f2bd9801db2782358b)
Continued on next page...
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