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Well assuming the tubing and flare tools aren't the problem, the only other thing that I could think of might be how you deburr the inside and outside of the tube where you cut it. Make sure it's even, maybe try one flare with more deburring and one with less. If that doesn't work call up fed...

What brand cunifer line are you using? I've only had consistently good luck with brakequip "ezi-bend" and fed hill, I believe all other lines in the shrink wrapped coil packages are made by the same mill with different labeling. They tend to be thinner wall harder copper so they don't bend as...

Check this first post for inexpensive DOT 5 http://www.steelsoldiers.com/showthread.php?123335-DEUCE-BRAKE-LINE-REFERENCE-GUIDE-(Sizes-lengths-fittings)&p=1539040&viewfull=1#post1539040