Best way to cut braded steel 5mm metric brake lines

[Kingaero]

I am working on a Team Dynamic WT9 installing an all new brake system. They sent steel braded lines that are plastic jacketed. I am trying to cut them with a dremel and a fine wheel. I am getting a few stray wires and the plastic jacket expands from the heat of cutting.

I have tried using dyke cutters and I still get a few stray wires. One is to many to be able to slide the ferrel on. I have tried taping the end before cutting. Still had stray ends. I know this can be done. Tell me you success story!

[vaflier]

Perhaps a pair of cutters for cutting wire rope might do a better job. Those are the ones with opposing curved jaws. Do not know if it will work , but just a thought. Also can you wrap one thin layer of tap around the hose and slide the ferrule over that and back out of the way and then cut the hose and sliide the ferrule forward ?????. Just thinking out loud. Good luck and pleas post what worked.

[1600vw]

How you work with this. Take black tape and wrap it in tape. You do not need a bunch of wraps but make them tight. Black tape is made to stretch. When installing it you pull on the tape and make it stretch some. Most do not use black tape correctly. But this is another story.
Then take a band saw and cut this with a band saw. You will cut the part that is wrapped with tape. You can use a hack saw but you must move it very fast and the blade needs to be of the fine tooth type. The trick here is to make sure you pull that tape tight and wrap it about 5 times.

Tony

[1600vw]

I bet that is why the blue shrink wrap is installed. Cut the tube on the blue shrink wrap. If it did not come with the shrink wrap do as I said in the above post.

[1600vw]

You can also cut this with one of these. But remember to wrap that with tape and make that tape tight.

http://www.harborfreight.com/14-in-2...saw-61389.html

[Kingaero]

Thanks for all your suggestions. I should have added that this was a 4mm line. Very small and the the steel brade very very small wire. I used the suggestions here and one provided by Lowell Farrand to use JB weld 5 min and a nicopress swaging tool as a former in the end. It kinda worked too but I still had a few stragglers. What I ended up doing was using a copper terminal end, swaging it on the hose with my nicopress and then cutting with the dremel and it worked. Thanks to my motorcycle buddy Dan Holmes who had to do this on some motorcycle brake lines in the past.

[Frank Giger]

Please tell me you took pictures of the process and are willing to share them.