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987.2 2.9: replacing hard brake lines.

911hillclimber

911hillclimber

PCGB Member
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Getting ready to replace a few rusty looking hard steel brake lines on my 92K mile Boxster.
Replaced several car's lines with copper nickle, so OK with that, but the line over the box is a bit un-clear.
Does this line run from the mid-car junction block right over the box to the rear caliper (drivers side)?
Have found Rocketdogracing's flexible hope which looks idea, anyone with experience of doing the job and what suppliers used please?
I know i need a new flare tool to do the bubble flare, rest seems pretty standard fare.

Any hints tips etc welcome.

Pic for a smile!

 
911hillclimber said:
Getting ready to replace a few rusty looking hard steel brake lines on my 92K mile Boxster.
Replaced several car's lines with copper nickle, so OK with that, but the line over the box is a bit un-clear.
Does this line run from the mid-car junction block right over the box to the rear caliper (drivers side)?
Have found Rocketdogracing's flexible hope which looks idea, anyone with experience of doing the job and what suppliers used please?
I know i need a new flare tool to do the bubble flare, rest seems pretty standard fare.

Any hints tips etc welcome.
Click to expand...

I had all the underbody lines on my 987 replaced with copper/nickel a couple of years ago.

The attached extract from the parts list will help you identify line runs. Each corner has a line back from the ABS control unit via a connector block on the LH front inner wing.
Page 1 (604-10) shows all the front underbody lines from the inner wing connector block to the front axle and the mid-body connector block for the rear lines. The tricky line at the front is number 9, which feeds through above the steering rack.
Page 3 (604-15) shows the two rear lines from the mid-body connector block. Number 8 is the tricky one, over the gearbox.

One warning, many of the plastic clips securing the lines to the body will have become brittle and can break easily.

At the same time I replaced all the flexible hoses with braided stainless steel reinforced lines.
 

Attachments

  • Pages from Boxster (986), 1997 - 2004.pdf
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What a reply Ian!
Thank you for the details.
The front pipes local to the flexible are lightly corroded, my plan is to cut and in-line connect Copper Nickle to repair.
Mid block to rear I have only seen corrosion locally, but will check far closer soon to see if it is best to simply replace the whole runs; I suspect I will do this, just simpler.

Last time I did this kind of repair was in 1989 on my 911's restoration...
 
Ian, if you read this..
Please can you tell me what dia tube you used and thus fitting sizes?
Are all the flares bubble type?
 
Firstly, as I said, I had them replaced, I didn't do the work myself. The last time I made up brake lines was almost 50 years ago. At my age, there are some jobs now that I am happy to leave to the professionals, and this was one.
I used a local garage who charged less than half the OPC rate. They sourced the pipe and fittings. I bought new pipe clips from the OPC as required. The final bill was less than the cost quoted for Porsche original lines, unfitted.
I wanted rid of ALL the steel lines under the car. My experience is that Porsche original lines are inferior to the lines on my daughters similar age VW...
 
Thanks Ian, sorry, I thought you had done the job!
At 74 I know I'm getting to the point where hard DIY is foolish...

I too want to do all the steel lines to cunifer, I think this will actually help selling in the future.

Big job, but a local garage could be a good route to check around here.
There are one or two generalists about some with classic experiences.

Thanks again, Graham.
 
911hillclimber said:
Thanks Ian, sorry, I thought you had done the job!
At 74 I know I'm getting to the point where hard DIY is foolish...

I too want to do all the steel lines to cunifer, I think this will actually help selling in the future.

Big job, but a local garage could be a good route to check around here.
There are one or two generalists about some with classic experiences.

Thanks again, Graham.
Click to expand...
FYI, I was charged for 14 hours labour. Not bad for removing, fabricating and fitting 10 pipes. With VAT, the bill (March 2025) was £1,130 excluding the parts I supplied (plastic clips from Porsche and the new flex hoses from D911).
Previous to this, the link pipes between the inner and outer halves of each caliper were replaced. I had been losing fluid due to a tiny pinhole that had developed on one of the rears. Not a common fail, I think water may have found its way inside the rubber protective sleeve onto the unpainted section of pipe. The sleeves were reused on the fabricated pipes.
 
Thank you for those details Ian.
Although a task I'll be going the DIY route, just not sure when but MoT due in late March.
 
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