Brake Lines (2025-2026)
CONTEXT YOU NEED BEFORE YOU PROCEED:
3AN = “3” indicates a tube outside diameter of 3/16 in. and AN comes from the universal Army Navy standard for fittings. It also has a corresponding male thread size of 3/8-24.
1/8 NPT = 1/8 NPT refers to a National Pipe Tapered thread, a US standard for threaded pipes and fittings, where "1/8" is the nominal (not actual) pipe size, meaning it connects to fittings with roughly a 3/8-inch outside diameter (OD) for male threads, using a 60-degree taper for a pressure-tight seal with sealant (like Teflon tape). These fittings are common in pneumatic, hydraulic, and plumbing systems for secure, leak-resistant connections, with 1/8-27 threads per inch.
(probably same explanation for 1/4NPT (which is what is used in this system) but when I put this here, it was 1/8 (source=trustmebro))
M10 = Metric 10mm diameter
FRONT CALIPERS
Summary of how everything connects:
Soft line from right master cylinder goes to a 4 WAY JUNCTION. The soft line ends as a female 3AN and will need a 3AN male to male adapter to connect the junction which has 4 Female 3AN ports. Two soft lines will come out of the 4 WAY JUNCTION and also need the same 3AN male-male adapter. The left hard line will go to the left, front caliper (same for right). Finally, the last port of the junction will be used for the sensor. The sensor has a male 1/4NPT end and will need an adapter. The adapter from the junction to the sensor is a 3AN male to 1/4NPT Female adapter.
BACK CALIPER
Summary of how everything connects:
Soft line comes into a 3 WAY FITTING that has two male 3AN ends and one female 3AN end. Soft line comes out of the 3 WAY FITTING to→ 3AN female to male adapter ->long line of hardline which goes to soft line (flaring and male to male adapter here) to the back caliper. 3AN male to 1/4NPT female goes into the 3AN female end of the 3 WAY FITTING. The pressure sensor then fits into this adapter with its male 1/4NPT end.
OTHER IMPORTANT COMPONENTS
Soft line coming from the left master cylinder will switch to hard line around the area of the pedal box plate (need flaring of hardline and 3/8-24 inverted flare FEMALE → -3AN MALE adapter). This hard line will then switch (need flaring of hardline and 3/8-24 inverted flare FEMALE → -3AN MALE adapter) back to soft line around the rear part of the frame to connect to the brake caliper. Soft line coming from hand brake switches (need flaring of hardline and 3/8-24 inverted flare FEMALE → -3AN MALE adapter) to hard line (long line along the rear of frame) and then switches(need flaring of hardline and 3/8-24 inverted flare FEMALE → -3AN MALE adapter) to soft line somewhere around the rear area of the frame to connect to the rear caliper.
Sharepoint BOM Link: https://utexas.sharepoint.com/:x:/r/sites/ENGR-LonghornRacing/_layouts/15/Doc.aspx?sourcedoc=%7BB3571953-41F6-43A2-BB41-D17834D4FC9E%7D&file=Brakes.xlsx&action=default&mobileredirect=true
^^^^MOST RECENTLY UPDATED BOM ^^^
SOFTLINE MEASUREMENTS:
40.33 left soft - 44
43.07 right soft - 48
LMC Outlet - 4.7684 - 6
RMC Outlet - 7.9761n- 9
26.0922 - HB(TarmCal)_RearSoftline - 32
19.4558 - LMC(TarmCal)_RearSoftline - 24
Component | Link | Amount needed |
|---|---|---|
ALT PLAN TO 4WAY 1/4” NPT Female to 1/8” NPT Male | 2 | |
ALT PLAN TO 4WAY 3AN 3 way tee (3 male) | 1 | |
4 Way Junction (1900 psi rating) (concave seat…should we find another, should we find a convex flare 3AN male to regular 3AN male, or is there another solution?) | 1 | |
Pressure Sensor | 2 | |
3AN Male to 1/4 NPT Female adapter | 1 | |
3 Way Fitting | 2 | |
3AN male to male adapter | 3 (3 for outlet of MC to softline) | |
Reservoirs | 3 | |
Hose for Reservoirs (5/16” compatible with 6AN MC inlet) | 2 | |
Soft Lines | 1 x 44'' 1 x 48'' 1 x 9'' 1 x 24'' 1 x 32'' 1 x 6” | |
Hard Lines (copper nickel alloy) comes with hardline nuts | 1 x 25' | |
Hardline to Softline Adapters 
| 2 orders | |
Brake Fluid | 1 | |
Worm Clamps for Hose (6-12mm) |
| 1 |
Banjo Fittings (Standard) | 4 | |
Crush Washers | 1 pack | |
45 degree double flare tool | WE HAVE A SET! | WE HAVE A SET! |
Hardline cutters | 1 | |
Inlet for Master Cylinder | 3 | |
Master Cylinders (5/8 bore size) | https://tiltonracing.com/product/78-series-master-cylinders/ | 2 |
Hand brake MC (.62in bore) | 1 | |
HB Inlet Fitting | 1 | |
Female to Female (3AN) | https://www.racetronix.biz/p/female-swivel-3an-al-black/adf-496103 -Steel Option: https://www.amazon.com/Podavelle-Straight-Stainless-Coupler-Connector/dp/B0CKBNCJGB | 1 |
Banjo Bolts (M10 x 1 (1 is thread pitch…should match caliper banjo hole) 25 mm (25.5 actual total length))
| 4 | |
Sealant for NPT threads | 1 |
Wilwood dh4 specs:
TWO 3 WAYS VERSION: $407.44 estimate
part count difference:
-2 M2M male adapters
-2 three ways 2fem and 1 male
-2F2F 3AN
-2 1/8 NPT to 1/4 NPT adapters
-1 3AN three way all male
4 Way Plan: $444.17 estimate
Part count difference:
-5 M2M male adapters
-1 F2F 3AN
-1 3AN Male 1/4 NPT Female adapter
-1 1/8 NPT male to 1/4 NPT female adapter
-1 3AN three way all male
4 Way Torque Specs:
SOURCES:
WHY I CHOSE
copper-nickel alloy over stainless steel: https://bludotinc.com/why-copper-nickel-brake-lines-are-superior-to-traditional-brake-lines/
specific inlet for the master cylinder:
Master cylinder doc specifies 6AN inlet. The resrvoir hose I am using is 5/16'' which corresponds to the reservoirs chosen which have an 8mm outlet (essentially the same thing).
Copper crush washers:
Copper is compatible with Dot4 brakefluid. Most Dot4 brake fluid sites explicitly say this. The one I got doesn’t explicity say it, but it is also cheaper than other options. https://laverdaforum.com/threads/brembo-copper-sealing-washers-vs-aluminum-aluminium.89879/
45 degree double flare vs single 37 degree flare:https://rbisj.com/2022/08/whats-the-difference-between-37-and-45-degree-flares/
MAKING A DOUBLE FLARE:
PSA: I AM NOT AN EXPERT. SOMEONE PLEASE DOUBLE CHECK THIS.