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rear caliper brake lines with rebuilt calipers - problems with flare ends

Bob, what usually causes this problem is that the flare is too large at it`s max. diameter due to incorrect flaring or, more commonly, previous over-tightening of the tube nuts causing expansion of the tube nut end where it contacts the flare making it too large to go into the thread.
This can usually be cured by carefull filing or grinding of the tube nut outer diameter at the flare end.
The bore of the threaded hole must be OK as you would not get a new nut to screw in if it wasn`t.
I doubt the rebuilder did any more than bead blast and inspect the caliper, hone the bore and fit new pistons and seals, re-machining of the body to repair the holes and thus alter the depth wouldn`t be economically viable.
Colin.






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