Please note 3/4" is the new MK2 version (radiused edges, larger bolt, flush bearing, sunken logo pocket) 1.25" and 1.75" our our original MK1 versions and have been discounted. Both MK1 and MK2 produce exactly the same finished flare shape. See photos.

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

The world’s best hole flares? 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.

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 (or dimple dies) tend to be a straight fold from horizontal down 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 is only limited by the method of bringing the male and female parts together. They will produce exactly the same finish on 0.5mm aluminium as they will on 3mm steel. Automotive flares however, are restricted by 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 alsdo added a small radiused transition from the horizontal to 45° 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 aircraft hole flares are machined in the UK from 4140 cromoly 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 location. Another advantage is our optional threaded pull rods to be used with a hydraulic knockout kit we sell for flaring material in situ, such as vehicle chassis or roll cage webs (see below for Knockout Kits & 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 SKF thrust race bearings recessed into the male upper and cap head bolts. This bearing halves the effort required to press the shape. As Airccraft Flares only create the shape and do not punch the hole we recommend the use of either our UK made Q-Max hole punches or the German made RIX Alfra range in conjunction with the flares for ease of use and accuracy over making holes with a regular hole saw. 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 small hand tools section) 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.

• Machined in the UK from 4140 cromoly steel
• Radiused 45° transition for use on any gauge material
• New Improved larger bolts
• Machined flats for vice mounting
• Internal thread
• SKF thrust races included
• Use by hand, by hydraulic punch or with workshop press
   

Flares are available separately or in kits as below.