CUSTOM HOSE FABRICATION

Fabrication scope and hose range

Whether you need a single replacement for a metric utility tractor or a high-volume run of custom assemblies for a local manufacturing plant, SIG Hydraulics builds to your exact specifications. Our primary facility in Salem, Ohio, is equipped for both fast walk-in walk-out repairs and scheduled contract production. We don’t just sell bulk hose. We build engineered assemblies designed to survive high vibration, extreme pressure cycles, and rough environments.

Our fabrication range covers standard hose inside diameters from 3/16" all the way up to 2" for high-flow return and suction lines. We stock a wide array of hose styles. This includes standard SAE 100R1 and 100R2 wire-braided hoses for medium-pressure systems. We also stock 4-wire and 6-wire spiral-reinforced hoses (SAE 100R12, 100R13, and 100R15) designed for constant working pressures up to 6000 PSI. For special applications, we stock thermoplastic hoses, non-conductive lines for utility trucks, and suction hoses with steel wire coils that won’t collapse under vacuum.

Fitting identification and inventory

The secret to a reliable hose is matching the fitting exactly. A thread that looks close but is off by a fraction of a millimeter will strip or leak under load. Our Salem shop is equipped with precision thread identification tools. We measure pitch, seat angles, and diameter. We stock standard American threads: JIC 37-degree flare, O-Ring Face Seal (ORFS), National Pipe Thread (NPTF), and SAE O-Ring Boss (ORB). We also carry a full inventory of metric and international fittings. This includes British Standard Pipe Parallel (BSPP), British Standard Pipe Tapered (BSPT), and Japanese Industrial Standard (JIS). We stock German DIN light and heavy series metric fittings. If your machine was built in Europe or Asia, we can match the thread.

Shop tooling

We use professional-grade shop tooling. Our primary shop press is a Uniflex HM465 400-ton industrial crimper. This machine delivers the massive force needed to crimp multi-spiral hoses up to 2 inches and large-bore industrial lines. The Uniflex crimper uses a split-die system that ensures even, 360-degree compression around the fitting collar. This prevents high-pressure leaks and collar slippage under extreme load cycles. Every crimp we make is measured with micrometer calipers and logged for quality control.

Cleanliness protocol

Cleanliness is a priority, not an afterthought. Dirt is the number one killer of hydraulic systems. When we cut a hose, the abrasive wheel leaves rubber dust and metal particles inside the tube. If you install that hose raw, that debris goes directly to your pump, relief valves, and cylinders. It scores the polished steel surfaces, causing internal leaks and premature pump failure. At SIG Hydraulics, we clean every custom assembly we build. We use an Ultra-Clean foam projectile launcher. We blow a clean, dry foam plug through the hose before crimping the second end. After crimping, we seal both ends with heat-shrink plastic caps. This keeps road dust, moisture, and shop dirt out of the hose during transport and storage.

Proof testing

To guarantee performance, we offer proof-testing. Our Salem shop houses a dedicated Uniflex P160 proof test bench. We test assemblies to full operational pressure or up to SAE J517 test specifications. The test bench is fully enclosed for safety. It can generate hydrostatic testing pressures up to 18,850 PSI. We provide physical or digital pressure test certificates when required. This is critical for municipal lifts, military logistics, and high-liability industrial systems.

Elbow alignment for complex assemblies

We also specialize in fitting angle alignment for complex dual-elbow assemblies. When building a hose with elbow fittings on both ends, the relative angle between the two elbows is critical. If the angle is off, the hose must be twisted during installation, which causes torsional stress and cuts its service life. We use specialized shop jigs to measure and set the exact angular displacement (in degrees) before crimping the collars. This ensures the hose seats naturally on your machine without twist.

Walk-in shop service

Our Salem facility also features a walk-in service counter. If you bring your damaged hose to our counter, our experienced technicians will identify, build, and clean a matching replacement while you wait. We understand that every minute of downtime is a loss. We maintain a huge inventory of adapter fittings and steel couplings to make sure we can build even rare or obsolete hose lines. You can grab a coffee, watch the fabrication process, and walk out with a completed, pressure-ready assembly in under fifteen minutes.

Asset management and labeling

We also offer custom labeling and asset management. We can mark each hose with custom aluminum tags or high-durability heat-shrink labels. We print part numbers, pressure ratings, installation dates, and QR codes. This makes replacement simple. If a labeled hose eventually wears out, you don’t have to bring the machine or the dirty hose to our shop. Just call us with the part number on the tag. We will build a duplicate assembly and have it ready for pickup or dispatch a truck to install it.

Production flexibility

We understand that custom fabrication requires speed. If you walk into our Salem shop with a broken hose, our goal is to build your replacement in under fifteen minutes. If you have a bulk order, we schedule production to minimize lead times. We work directly with maintenance managers, plant engineers, and independent operators. No job is too small, and no custom run is too complex. We have the inventory, the machinery, and the experience to deliver exact, clean, and pressure-tested assemblies every time.