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Hey Pete, I know you've done a lot of this kind of work, but what kind of flare wrenches are you using? Any but the best will spread under load and round the fittings. Basically, if you don't have Snap-On flare wrenches then toss them dustbin where they belong and spend the big bucks to get yourself a proper set.
For you existing problem, try a tool that tightens under load, like a small 6" pipe wrench. I think you guys call them Stillson wrenches? Again, you'll need top quality with sharp jaws (like Rigid) or you'll just make it worse.
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'99 black 986
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