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  #1  
Old 20 Mar 2004
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Brake hoses

Does anyone know of a source of Stainless steel braided brake hoses of 1/8 inch internal diameter? A local supplier of hydraulic equipment says that he just can't get hold of the stuff, he says it's a closed market. I've worked with 1/4 inch hydraulic hoses and fittings before and was surprised that it was so straightforward; so is there anybody out there with experience of fabricating brake hoses?

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Old 20 Mar 2004
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I've made my own brake hoses for years. You mentioned 1/8" internal ID - in my experience, it's not the diameter, internal or external, you should worry about. You need to get the correct fittings for your calipers & master cylinders i.e. 10 x 1.25 OR 10 x 1.50mm pitch. Any worthwhile supplier would automatically supply you with the correct lines when you buy the fittings.

I'm assuming your looking to fit new lines to an airhead? - please note that the airheads & K series I've fitted lines to have required shortening the banjo bolts by a few mm, both for the calipers & the m/cylinder. Short banjo's are available but I gave up trying to find them, so I shorten them myself on a lathe.

I buy all components from RaceParts in Wallingford, just south of Oxford. Phone number is 01491 - 822000.

They also have a quick/easy-release option where a double ended hex screws in to the caliper via a copper washer. Protruding upwards is another threaded end that the brake line screws on to via a swivel fitting, similar to some oil cooler hoses but smaller. Benefit of this is that you don't have to worry about hose fitting alignment i.e. avoids twisting & you can remove the caliper very easily without disturbing/replacing the copper washer - e-mail me if you want a photo by return e-mail?

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Old 20 Mar 2004
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Many thanks for your speedy response, Steve. I mentioned the bore of the hose because that's the size of the hose originally fitted to the bike: an R100RS, 1982, it's marked DOT C 08/81 1/8 HL. It seemed logical to stick to that size. I must say that I'm puzzled at your mention of a banjo type fitting, there's none on mine. Actually, I'd rather avoid them if possible as a sideways clout could slacken them off. I've made a note of your supplier, RaceParts; it's too late to try them now, I'll give them a bell first thing Monday.

Many thanks

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Old 22 Mar 2004
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Both my g/f's R80GS & mine have banjo bolts fixing the brake line to the master cylinder. Some older R series possibly had a cable operated m/cyl fitted with inline hose fittings?

In addition, when fitting regular stainless fittings to the caliper, I still had to machine them - if you end up with these "long" fittings, let me know & I'll shorten them FOC if you supply dimensions.

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Old 23 Mar 2004
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Hi, Steve
Just had a word with RaceParts and they were very helpful, I've promised to send them a photo of my current setup; they estimated about ten quid per hose with cadmium plated fittings and a bit more for stainless. And they'll do the assembling for free. Ah, yes, quite right, I do have a banjo fitting on the master cylinder. Thanks. I'll let you know how I get on. Before I go, anyone have any thoughts on Dot5 instead of Dot4 brake fluid? I've tried both, but have heard that Dot5 doesn't absorb moisture like Dot4. Also, Dot5 doesn't provide as much lubrication to the pistons and seals. Cheers

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Old 23 Mar 2004
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I would not bother with DOT 5 - it's primarily for race bikes.

Just buy the stainless lines & fittings. At some point the Cadmium fittings will rust. If you buy stainless from RaceParts, it will cost a little more than £10.00 per line. At Xmas I paid £31.00 for 1.2m of line, all stainless fittings inc. the q/d set up previously mentioned & the necessary copper washers & olives & 1.2m of black plastic spiral wrap to protect the line from chaffing anywhere.

If you want the q/d parts & have trouble getting them, let me know & I'll phone Race Parts to remind them of the part numbers - I have the invoice at home.

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