Stakesy’s® E-Range Automotive Style Punch and Flares

When we designed our Stakesy's flares 5 years ago we looked at the US made hole flares from Mittler Bros., JMR, Pro-Tools and SWAG and took the best features from all to create what we think are the perfect hole flare. Some customers wanted the same features but in a more affordable package so we have created the E-Range.

Rather than using Cromoly we have used an EN8 mild steel and heat treated the finished item. Bolts are still cap heads and optional thrust races can be purchased on a separate listing if you want to reduce the friction and make it easier to tighten down under load. E-Range hole flares come supplied with double washers as standard so just add some oil and try before upgrading to bearings.

Aircraft flares and automotive flares – what’s the difference?

Automotive flares have a radiused transition from horizontal to vertical and tend to be a deeper flare than an aircraft flare. Because the material is pressed down into a vertical finish the material is highly stretched. This is fine for most grades of aluminium but aircraft grade aluminium can be very hard and if stretched this much, could lead to cracking of the material (not good on an aircraft!). Because of this aircraft flares were designed and tend to be a straight fold from horizontal to 45 degrees which is easier on the material but arguably slightly less visually attractive. The other benefit of an aircraft flare over an automotive flare is that the thickness of the material doesn’t come into play. They will produce exactly the same finish on 0.5mm aluminium as they will on 3mm steel. Automotive flares however, are restricted to the vertical clearance between the male and female parts of the tool so are only effective on material thicknesses from 1.0mm – 2.0mm max. You could not physically get 3mm steel between the tool parts vertically. When we designed our aircraft flares we added a slight radiused transition from the horizontal for appearance but left the finish at 45 degrees so they will work with any material type and thickness. Best of both worlds.

Stakesy’s E-Range automotive style punch and flares are machined from heat treated EN8 steel. We machined an internal thread in the female rather than drilling straight through. This negates the need for a nut and also makes for more accurate docking. Another advantage is an optional threaded pull rod to be used with a hydraulic hole punching machine we sell for flaring material in situ such as vehicle chassis or roll cage webs.

We machined a flat on the female part of the die, enabling it to be held in a vice for manual flaring, or for use with a large spanner. All flares come with cap head bolts fitted as standard. 

We recommend the use of our SD42 pressing lubricant for a perfect finish and tool protection.

Finally, for heavier gauge steels the tool can be used in a workshop press. 3 options; by hand, by hydraulic punch or by workshop press.

• Machined flats for vice mounting
• Internal thread
• Use by hand, by hydraulic punch or with workshop press

Flares are available separately or in kits as below.