Stakesy’s® E-Range Aircraft Style Sheet Metal Hole Flares / Dimple Dies

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Stakesy’s® E-Range Aircraft Style Sheet Metal Hole 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.

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 aircraft hole flares are machined from heat treated EN8 steel. The swage angle ranges from 43-45% depending on size. 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 (see below for Slugbusters & Pulls Rods)

We machined a flat on the female part so you can hold it 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 UK made Q-Max hole punches in conjunction with the flares for ease of use and accuracy over hole saws. These are available to buy with each Flare on the dropdown menu to your right. Always deburr the hole first with a rotary deburrer (see other items) and use tapping oil or 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.


  • Radiused 45deg transition for use on any gauge material

  • 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.

ESAF075 0.75"  
ESAF075QM 0.75" + Q.Max Cutter  
ESAF1 1"  
ESAF1QM 1" + Q.Max Cutter  
ESAF125 1.25"   
ESAF125QM 1.25" + Q.Max Cutter  
ESAF15 1.50"   
ESAF15QM 1.50" + Q.Max Cutter  
ESAF175 1.75"  
ESAF175QM 1.75" + Q.Max Cutter  
ESAF2 2"   
ESAF2QM 2" + Q.Max Cutter  
ESAF11pc 0.5" + 0.75" + 1.0" + 1.25" + 1.50" + 1.75" + 2.0" + 2.25" + 2.50" + 2.75" + 3.0"  
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Delivery & Returns

Items under 30kg will be shipped by either 24hr courier or 1st class Royal Mail depending on item and weight and size.
All orders will be packaged and despatched same or next day. Orders made later in the day will most likely be sent out the following day.
We use a Next Day Delivery service however this service is subject to stock, courier availability and courier area. A signature is required for courier deliveries so please arrange for someone to be in at delivery address.   

Delivery prices are calculated by total order weight & size and are as follows:


UK Mainland

Highlands & Islands










45kg +



Buying from outside GB Mainland.

We are happy to deliver worldwide upon request. Because of the many variables involved our website cannot calculate global shipping or deduct UK Tax, please call on +44 1509 812171 or email and we will work out the best price for you.

Heavy Goods Items/ Pallets

If you are ordering to Mainland UK or Highlands and Islands, once added to your basket, our shipping calculator will work out a shipping price depending on your delivery post code. Delivery can take up to 4 working days from point of order but is often sooner depending on location. We will call to let you know estimated delivery date, you may be required to help the driver move the product from the roadside to your desired location, please ensure somebody is in to receive the goods as there is a redelivery charge of £30 should you miss it.

We also ship heavy goods and pallets worldwide, however not through the website, please call on +44 1509 812171 or email

Returns Policy 
Stakesy’s Guarantee: 14 Day Money Back Guarantee 

1/ Items returned under the 7 working day cancellation period 
If for any reason you are unhappy with your purchase, you can return it to us in its original condition within 7 days of the date you received the item, unopened (with any seals and shrink-wrap intact) and we will refund the cost of the item and the cost of sending the item to you as follows: 
-where you are returning an item that was part of a larger order, we'll refund the per-item charge for delivery that you incurred -where you are returning an entire order, we'll refund all delivery charges that you incurred -we will refund only standard shipping charges for items delivered mainland UK (excluding Highlands & islands and orders over 25 kilos in weight)

2/ Items returned under 14-day returns guarantee 
Where you are withdrawing from your purchase between 7 and 14 days after delivery, and there has been no error on our part, we will refund only the cost of the item minus 10% handling charge. We will not refund the cost of delivery or other services provided to you in connection with your purchase.

3/ Any goods items over 60 kg that have incurred special freight charges are excluded and the buyer will be responsible for both arranging and the costs of the return delivery.

Refunds will be paid within thirty days of cancellation. 

Please post goods to be returned or exchanged to:

Stakesy’s Metalwork Machinery, Unit 12 Hayhill Industrial Estate, Loughborough, LE12 8LD.

It is crucial that you pack the goods to be returned the same way as we sent out. Please consider that a returned item that is damaged in return transit may well be un-refundable if we cannot re-sell. Please include a note of your requirements and original invoice number.