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Custom Cooling

Putting a bead on your tubing

Hot rods, racecars and customized vehicles frequently require extended hose runs to hook the cooling system components together. Often the engine is set farther back, well away from the radiator, or in some cases there are a number of radiators plumbed together in series or tandem. Whatever type of cooling system, some custom fabrication is usually needed.

Connections

Rubber hoses should not be used in long runs, so metal tubing (aluminum or steel) is recommended. The choice of steel or aluminum is up to you. Aluminum is lighter but steel is cheaper and easier to bend. (Corrosion inhibitors in anti-freeze and products like Water Wetter will help keep rust at bay.) Whatever type of metal tubing you choose, it must be beaded on each end, if there's a hose clamped onto the tube, or the hose will blow off.

Security

A bead is a small raised area around the perimeter of the tube that the hose will slide over. Once the hose has been clamped in place over this bead, it will stay on securely even with the buildup of heat and pressure.

There are several ways to bead the end of a metal hose. The simplest way is to take it to a fabricating shop that has a beading tool the proper size for the tube. They can roll a bead onto the end of the tube for a nominal fee (about $25).

Beadwork

However, if you cannot locate a shop with a beader, there are two other options. One is to weld a bead around the perimeter of the tube, then file and dress it to a proper shape. This is a lot of work and, unless you are an experienced welder, probably not your best option. The other is to weld a slice of tubing on the end of the tube, as shown in the accompanying photos and captions.

The method you choose is not as important as remembering to do it. Without beads, your cooling system's tubing is like that proverbial horseshoe nail that lost the kingdom. Without a bead, you could overheat an engine or, at the very least, lose a lot of coolant fluid.