Thanks for all the compliments, everyone! Regarding the tube flaring, I used some 1/4" OD brass tubing I bought off eBay some time ago. This forum contains a bunch of flaring tutorials and I followed these, using my vise and some simple flaring dies I made up. Careful measuring, attention to detail and a will to persevere does the rest!
Here are some threads for reference - my method follows the same principles:
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