Dealing with a burst high-pressure pipe in your car, especially in a tight spot like in my Citroen Xantia, can be a mechanic’s nightmare. When a critical pipe running from front to back decided to give way, accessibility issues made a full replacement a daunting task. The most practical solution? Replacing just the corroded section. The plan was straightforward in theory: cut out the damaged part, flare the existing pipe ends, and splice in a new section using in-line connectors. This is where the challenge of needing Car Parts Made With A Punch And Flare Tool became very real.
My existing bench-mounted flaring tool, a reliable Pleiades model from years ago, wasn’t designed for on-vehicle work. While some might manage to use such tools in situ, their cam-operated nature makes it awkward. Investing in a specialized on-car flaring tool seemed inevitable. The BeePro from Germany is an excellent example, but with shipping to the UK, the cost soared over £350. Finding a more affordable alternative proved difficult. So, I decided to take a DIY approach, leveraging the punches and dies from my Pleiades tool to create a custom, vehicle-friendly solution. Hopefully, this project inspires fellow DIY enthusiasts and sparks ideas for further improvements in crafting car parts made with a punch and flare tool.
My quest began with a sturdy piece of U-channel steel from my reclaimed metal stash – perfect for the tool’s body. The other components were then fashioned to integrate seamlessly with this base.
Given the necessity for on-car operation and the force required for flaring steel pipes, a screw-operated mechanism was essential. I opted for a robust M20 x 1.0 pitch threaded bar to handle the pressure.
This image showcases the tool’s components roughly two-thirds of the way through the fabrication process, illustrating the assembly taking shape.
Here’s the almost complete main body of the tool. Note that the punches and dies shown are DIN style, different from those specifically for Citroen applications, but crucial car parts made with a punch and flare tool concept remains universal.
My initial attempt to flare a steel pipe with the prototype was, admittedly, a bit underwhelming.
I had slightly deviated from my original design by adopting the newer screw-in punch style, aiming to simplify the integration of an extraction mechanism. However, I soon realized that this newer punch was narrower than the original and fitted too loosely within the dies. This discrepancy explained the uneven flare. (The original Pleiades punch is on the left for comparison, with the new style on the right). Understanding these nuances is key when working with car parts made with a punch and flare tool.
To rectify this, I machined a sleeve to increase the diameter of the new punch, matching it to the dimensions of the original.
This close-up illustrates the punch holder and its fit over the compression screw. The design cleverly allows the punch to retract as the screw is unwound, simplifying the process. This extraction feature is a beneficial refinement in car parts made with a punch and flare tool, especially for on-car applications.
The completed tool, now sporting a protective coat of spray paint, ready for action.
Putting the homemade flaring tool to work on the Citroen Xantia’s pipe repair.
The moment of truth – the successfully flared pipe end, achieved on the car.
If I may say so myself, I was genuinely thrilled with the outcome. This DIY project proves that with a bit of ingenuity and resourcefulness, creating specialized car parts made with a punch and flare tool for specific repair needs is entirely achievable, saving significant costs and expanding your automotive DIY capabilities.
