Flexhone for Cylinders - Instantly improve Ra and surface finish!

the Flex-Hone® Tool

BRM's Flex-Hone Tool is protected by...
USA Patent Numbers 3384915, 3871139, 5211725, 5353553
US & Foreign Patents Allowed or Pending

For Any Type And Size of Cylinder
The Flex-Hone® Process (Super finishing) produces a controlled surface condition unobtainable by any other method. It involves finish, geometry and metallurgical structure. A high percentage plateau free of cut, torn and folded metal (with radiused ports).

A resilient, flexible, honing tool with a soft cutting action. The abrasive (points) globules each have independent suspension that assures the Flex-Hone® to be self-centering, self aligning to the bore, and self-compensating for wear.

Specifically, it is a low-temperature abrading process that exposes the undisturbed base metal structure to produce a long wearing surface. It is a method of developing a surface on a metal part which is optically smooth and metallurgically free of any fragmented, amorphous or smeared metal from previous operations. It is accomplished at a low pressure where the “stones” float.

See and read the various booklets of actual tests covering almost every situation that will ensure a superior performance in situations depending on surface finish.

The particular type of Flex-Hone® crosshatch is extremely efficient in providing a multiplicity of oil grooves or valleys for oil retention as opposed to the often undirectional or uneven valleys common to the conventional type rigid hone. A crosshatch that usually remains as the cylinder wall has been wear-reduced by the FlexHone®.

If Your Specifications Call For:

Developing a surface plateau of over 60%
Producing an oil holding cross-hatch pattern
Reducing Ra, Rpk and Rvk values
Increased bearing area

If You Want benefits of:

Lowered oil consumption
Less blow-by
Less friction
Improved sealing surface

Flex Hone Tool

Then Flex-Hone® it!
Typical Applications Include:

Air Compressors • Compressed Air Tool Bodies • Hydraulic Ram Cylinders • Brake Cylinders (Wheel)
Hydraulic Valve Bodies & Valve Guides • Clutch and Brake Master Cylinders
Hydraulic Motor Bodies • Finishing of Stainless Steel Tubing
Pneumatic Cylinders • Brake Rotors
Surface finishing of Boiler Components • Engine Cylinders and Block Liners

Although the FLEX-HONE® TOOL is manufactured in an extensive range of diameter sizes and grits that suit most applications, there will be times that the Flex-Hone® Tool must be tailor made to achieve the results you may require. Please consult factory for pricing and delivery time on all special order, special application hones.

Flex Hone Tool

Abrasive Options

	Grit Sizes
Abrasive Types	20	40	60	80	120	180	240	320	400	600	800
SC=Silicon Carbide	X	X	X	X	STANDARD	STANDARD	STANDARD	X	X	X	X
AO=Aluminum Oxide	X	X	X	X	X	X	X	X	X	X	X
BC=Boron Carbide	X	X	X	X	X	X	X	X	X	X	X
WC=Tungsten Carbide
(either 100% or 50/50)	X	X	X	X	X	X	X	X
Z Grain - Alumina Zirconia
No.1525 (25%Zirconia/75%Alumina)			X	X	X	X	X	X
Z Grain - Alumina Zirconia
No.1549 (40%Zirconia/60%Alumina)					X	X	X	X
Levigated Alumina	Available in extra fine grit only

Flex Hone Tool

To assist in selection of proper hone, this information is a good starting point. Actual measurements
must be made after honing, as numbers will vary depending on the material being honed and the media used.

Grit Finish Range

800 grit	Ra 3-10	.05 - .2 Micrometer
600 grit	Ra 8-12	.2 - .3 Micrometer
400 grit	Ra 10-20	.3 - .6 Micrometer
320 grit	Ra 18-30	.5 - .7 Micrometer
240 grit	Ra 24-32	.6 - .8 Micrometer
180 grit	Ra 30-40	.7 - . 1 Micrometer
120 grit	Ra 35-50	.9 -1.4 Micrometer
80 grit	Ra 45-64	1.2 - 1.6 Micrometer
60 grit	Ra 60-80	1.5 - 2 Micrometer
40 grit	Ra 70-125	1.7 to 3.2 Micrometers
20 grit	Ra 125-250	3.2 to 6.3 Micrometers

What size should I order?

A hone tool's diameter is determined by the nominal bore size in which the tool is to be operate. A cylinder hone is always produced and used in an oversize condition. The degree of oversize creates pressure and a soft cutting action on cylinder walls. For example a 1" Flex-Hone tool is ordered if a 1" bore (I.D.) is to be finished, the built in oversize provides the proper cut. Remember that all tools are provided in oversized, so do not add inches or mm's to the ID that you are machining. If the bore size is between standard Flex-Hone sizes, the next larger standard Flex-Hone should be selected.

Important note:

If the Ra (surface finish) of the part being machined needs to change more than 20 to 30 points, you may need to use steps to acheive the proper final Ra. As an example, if you were trying to change a 80 Ra to a 20 Ra, you may need to start with a 120 or 180 grit hone and then finish with a 240 or 320 grit. This stepping concept reduces the chance of damaging the tool due to over heating, when too fine a grit is used for an extended run time to try and remove excessive roughness.

Brake Cylinders, Hydraulics, Valve Guides, etc.

4mm - 3/16" are 6" OAL
Balance 8" OAL

Catalog Number	MM	For Bore Sizes
BC 4mm	(.157")
BC 4.5mm	(.177")
BC 3/16"	(4.75mm)
BC 5mm	(.197")
BC 5.5mm	(.217")
BC 6.4mm	(.250")
BC 7mm	(.276")
BC 8mm	(.315")
BC 9mm	(.354")
BC 9.5mm	(.375")
BC 10mm	(.394")
BC 11mm	(.433")
BC 12mm	(.472")
BC 1/2"	(12.7 mm)
BC 14mm	(.552")
BC 5/8"	(16 mm)
BC 18mm	(.709")
BC 3/4"	(19 mm)
BC 20mm	(.787")
BC 7/8"	(22 mm)
BC 15/16"	(23.8 mm)
BC 1"	(25.4 mm)
BC 1 1/8"	(29 mm)
BC 1 1/4"	(31.8 mm)
BC 1 3/8"	(35 mm)
BC 1 1/2"	(38 mm)
BC 1 5/8"	(41 mm)
BC 1 3/4"	(45 mm)
BC 1 7/8"	(48 mm)
BC 2"	(51 mm)
BC 2 1/8"	(54 mm)
BC 2 1/4"	(57 mm)
BC 2 3/8"	(60 mm)
BC 2 1/2"	(64 mm)
BC 2 5/8"	(67 mm)
BC 2 3/4"	(70 mm)
BC 2 7/8"	(73 mm)
BC 3"	(76 mm)

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Disc Brakes

(5" OAL)

Catalog Number	MM	For Bore Sizes
DBC 1 1/2"	(38 mm)
DBC 1 3/4"	(45 mm)
DBC 2 1/8"	(54 mm)
DBC 2 1/2"	(64 mm)
DBC 2 3/4"	(70 mm)
DBC 3 1/8"	(79 mm)

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Block Cylinders or Liners

Heavy-duty Flex Hones®
3 thru 4 1/2” dia. are 13 1/2” OAL, with Balance at 17 1/2” OAL

Catalog Number	MM	For Bore Sizes
GBD 3"	(76mm)	3" to 2 3/4"
GBD 3 1/4"	(83mm)	3 1/4" to 3"
GBD 3 1/2"	(89mm)	3 1/2" to 3"
GBD 3 3/4"	(95mm)	3 3/4" to 3 1/4"
GBD 4"	(101mm)	4" to 3 1/2"
GBD 4 1/4"	(108mm)	4 1/4" to 3 3/4"
GBD 4 1/2"	(114 mm)"	4 1/2" to 4"
GBD 5"	(127 mm)	5" to 4 1/2"
GBD 5 1/2"	(140 mm)	5 1/2" to 5"
GBD 6"	(152mm)	6" to 5 1/2"
GBD 6 1/2"	(165mm)	6 1/2" to 6"
GBD 7"	(178 mm)	7" to 6 1/2"
GBD 7 1/2"	(190mm)	7 1/2" to 7"
GBD 8"	(203mm)	8" to 7 1/2"

Flex-Hone® Brake Cylinder Kits For Japanese and European Cars
BC Kit A (18 mm 22 mm 29 mm ) 320 Grit Aluminum Oxide
BC Kit B (25 mm 29 mm 35 mm) 320 Grit Aluminum Oxide
BC Kit C (41 mm 51 mm 60 mm ) 240 Grit Silicon Carbide
For Compact, Medium and Large Cars
BC Kit D (18 mm 20 mm 22 mm 25 mm 29 mm) 180 Grit SC
BC Kit (22, 29, 35 mm) 120, 180, 240 SC

Flex-Hone® Disc Brake Caliper Kit For Japanese and European Cars and Light Trucks
DBC Kit E (38 mm 45 mm 54 mm 64 mm ) 320 Grit SC
DBC Kit (45, 54, 64, 70, 79 mm) 180SC

Valve Guide Kits-Transmission Bodies
VGF Kit (6.4 mm 7 mm 8 mm 9 mm 9.5 mm 10 mm 11 mm)
240 Grit Silicon Carbide

* Kit has a savings of 10% over individual purchases.

Flex Hone Tool

Heavy Duty

Hex Shaft is 34"OAL

Catalog Number
3" Core (1/2" Hex Shaft)
GBDH 8"	(203mm)
GBD 8 1/2"	(216 mm)
GBD 9"	(228 mm)
GBD 9 1/2"	(241 mm)
GBD 10"	(254 mm)
4" Core (1/2" Hex Shaft)
GBD 10 1/2"	(267 mm)
GBD 11"	(280 mm)
GBD 11 1/2"	(292 mm)
GBD 12"	(305 mm)
5" Core (5/8" Hex-Shaft)
GBD 12 1/2"	(318 mm)
GBD 13"	(330 mm)
GBD 13 1/2"	(344 mm)
GBD 14"	(355 mm)
6" Core (5/8" Hex Shaft)
GBD 15"	(381 mm)
GBD 16"	(406 mm)
8" Core (5/8" Hex Shaft)
GBD 17"	(432 mm)
GBD 18"	(457 mm)

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Extra Heavy Duty

Shafts are 3/4" to 1 1/4" All 120SC

Catalog Number	MM	Drum Diameter	Section	# of Drum Sections	Shaft Diameter
GBDX 19"	(483 mm)	11 1/2"	A	22	3/4"
GBDX 20"	(508 mm)	11 1/2"	B	22	3/4"
GBDX 21"	(533 mm)	11 1/2"	C	22	3/4"
GBDX 22"	(559 mm)	11 1/2"	D	22	3/4"
GBDX 23"	(584 mm)	15 1/2"	A	29	3/4"
GBDX 24"	(610 mm)	15 1/2"	B	29	3/4"
GBDX 25"	(635 mm)	15 1/2"	C	29	3/4"
GBDX 26"	(660 mm)	15 1/2"	D	29	3/4"
GBDX 27"	(686 mm)	19 1/2"	A	36	1"
GBDX 28"	(711 mm)	19 1/2"	B	36	1"
GBDX 29"	(737 mm)	19 1/2"	C	36	1"
GBDX 30"	(762 mm)	19 1/2"	D	36	1"
GBDX 31"	(787 mm)	19 1/2"	E	36	1"
GBDX 32"	(813 mm)	24 1/2"	A	44	1 1/4"
GBDX 33"	(838 mm)	24 1/2"	B	44	1 1/4"
GBDX 34"	(864 mm)	24 1/2"	C	44	1 1/4"
GBDX 35"	(889 mm)	24 1/2"	D	44	1 1/4"
GBDX 36"	(914 mm)	24 1/2"	E	44	1 1/4"

GBDX Replacement Sections Available For Above GBDX Flex Hone Tools

Catalog Number	Grit Size	Overall Trim
GBDX-A Section	120SC	4 1/8" (105 mm)
GBDX-B Section	120SC	4 5/8" (118 mm)
GBDX-C Section	120SC	5 1/4" (133 mm)
GBDX-D Section	120SC	5 3/4" (146 mm)
GBDX-E Section	120SC	6 3/8" (162 mm)

Speciality Flex Hone Tools

Flex-Hone® Tools for Handguns

Flex-Hone® Tools for polishing revolver cylinders 3” OAL

	400SC	800SC
.357 MAG./.38 CYLINDER	00899	00900
.41 MAG. CYLINDER	00901	00902
.44 MAG CYLINDER	00903	00904
.45 ACP CYLINDER	00905	00906
.45 COLT CYLINDER	00907	00908

	400SC	800SC
1911 Main Spring Housing 4" OAL	00909	00910
1911 Slide Lug Area - 8" OAL		BC18M800
S&W, Beretta, Sig. Semi-Auto Internal Slide - 8" OAL		BC12800

Speciality Flex Hone Tools

Flex-Hone® Tools for Shotguns

With protective stem coating.

Barrel Flex-Hone® Tools 34" OAL
	180SC	800AO
10 Gauge	00607	00608
12 Gauge	00048	00049
16 Gauge	00050	00051
20 Gauge	00052	00053
.410 Bore	00609	00610

Chamber Flex-Hone® Tools 12" OAL
		800AO
10 Gauge		00611
12 Gauge		00054
16 Gauge		00055
20 Gauge		00056
.410 Bore		00612

Speciality Flex Hone Tools

Flex-Hone® Tools for Paintball Guns

With protective stem coating.

Barrel Flex-Hone® Tools 18" OAL
	180SC	600AO	800AO	Levigated Aluminum
.68 CAL	00750	00733	00461	01199

Rear Bore Flex-Hone® Tools 10" OAL
		600AO	800AO
RB .850		00642	00734

Gun brushes made in stainless steel or phosphor bronze fill. Pro Player and Airsmith kits are also available.