Mercedes Mullins
Plumbing a race car's fuel system can be daunting, but careful planning can make the process straightforward. The amount of fuel line needed to plumb a race car depends on the car's make and model, as well as the type of fuel system being installed. The plumbing process involves selecting the appropriate fuel lines, hoses, and fittings to ensure reliable performance. Factors such as material compatibility, pressure specifications, and proper routing are crucial to consider when determining the required fuel line length and configuration. Additionally, regulations from the track or sanctioning body should be considered to ensure compliance.
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What You'll Learn
Hose material: Teflon/PTFE, rubber, or metal
When plumbing a race car, it is important to select the right hose material to ensure the reliability of the vehicle. The most common materials used for fuel lines are Teflon/PTFE, rubber, and metal.
Teflon/PTFE
PTFE, or polytetrafluorethylene, is a synthetic polymer commonly known by its brand name, Teflon. It is a stable material that can withstand a wide range of temperatures and is chemically inert to most substances, except acid. PTFE hose products are known for their durability and resistance to degradation when exposed to corrosive fuels such as methanol, ethanol, and racing fuels like E85. This makes them ideal for use in racing applications, as they can handle extreme burst pressures and are compatible with most fluids, including racing oils, brake fluid, and coolant. PTFE hoses also have a small outside diameter in relation to their bore size, making them suitable for tight installations. Additionally, they prevent the escape of fuel vapour, eliminating the stale fuel smell that can occur with rubber hoses.
Rubber
Rubber hoses, such as those made from hydrogenated nitrile butadiene rubber (HNBR) or CPE, are typically less expensive than PTFE options. They are flexible and can be used in long lengths, but they require more supporting clamps to keep them in place. However, rubber hoses are susceptible to deterioration and degradation over time. They can harden, crack, and leak, and may not be compatible with certain types of fuel, leading to contamination issues.
Metal
Metal hoses, typically made from braided stainless steel, offer excellent protection against cuts and abrasion. They are often used as an outer casing for PTFE hoses to enhance their durability. Metal hoses are approved for use in racing applications and can withstand high pressures, making them suitable for severe pressure applications.
When choosing the hose material for a race car's fuel line, it is important to consider factors such as compatibility with the type of fuel and other fluids used, resistance to degradation and contamination, flexibility, and cost. While PTFE hoses are generally more expensive, they offer superior performance and durability compared to rubber and are less likely to cause issues due to fuel incompatibility.
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Hose size: 5/16-inch, 3/8-inch, or 1/2-inch
When selecting fuel lines for race cars, the choice is typically between synthetic rubber lines and PTFE hoses. While bigger doesn't always mean better, it's important to choose the right components for your application.
If you're using a 5/16-inch fuel line, you might start having trouble with the line size at just over 500 HP. Upgrading to a larger fuel pump, hard fuel lines, injectors, and a fuel rail may be necessary at this point.
For 3/8-inch fuel lines, Chevy engineers say that this size will feed enough gasoline to support 2200 horsepower. However, some users have reported having issues at just over 500 HP, while others have reported no problems at around 525 flywheel HP.
If you're looking for more capacity, a 1/2-inch fuel line is recommended for safety at 550 HP. This size is also less likely to be restricted by common adapters and fuel line fittings, which often have an inner diameter significantly smaller than 3/8 inches.
It's important to note that the type of pump you're using also matters. A big mechanical pump may not perform well with a small line, while an electric pump that pushes the fuel might handle it better. Additionally, the number of fittings and bends can impact performance, with tighter bends potentially causing issues.
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Hose fittings: stainless steel, alloy, or steel
When plumbing a race car, it is important to select the right hose and fittings for your application. Hose fittings are used to connect two hoses together, or to connect a hose to a tap, appliance, or equipment. They are distinguished by their connection type and function. The type of fitting required is the first point to check when plumbing a fuel system. Most production cars will have push-on hose all the way through, with 8mm bore push-on hose being the most likely.
There are several types of hose fittings:
- Crimp fittings: These require placing a hose over a cylindrical end and pressing it with a sleeve or crimp socket.
- Barbed fittings: These involve connecting hoses using a barbed tube with a narrow end, with its edges inserted into the hose. They are suitable for low-pressure applications.
- End fittings: These allow certain surfaces to make hose connections. Clamp end fittings allow the hose to be fastened to the connection, while plain end fittings allow the hose to be connected using an adhesive, soldering, or other forms.
- Compression fittings: These are used to connect two hoses by compressing with the help of a compression nut and a ferrule.
Hose fittings can be made from a variety of materials, including stainless steel, alloy, carbon steel, brass, and aluminium. Here is a breakdown of the benefits of each:
Stainless Steel
Stainless steel hose fittings are durable, corrosion-resistant, heat-resistant, and suitable for high-pressure applications. They are a better option compared to carbon steel fittings as they have thinner walls, reducing weight and dimensions for the overall assembly. They can also withstand a wider range of temperatures without exhibiting structural deformation, increasing their durability. Stainless steel fittings are more expensive than carbon steel, but their running costs are lower. Stainless steel is also easy to install and remove and is available in different sizes and shapes.
Alloy
Alloy fittings are available in red, blue, or black.
Steel
Steel is the most common material for hose assemblies for hydraulic systems. Low to mild steel is a better alternative for hose end fittings as it is easier to manufacture and work with compared to high carbon steel. However, it may rust easily without protective coatings.
Other materials used for hose fittings include brass and aluminium. Brass is a malleable, durable metal that is highly corrosion-resistant. It is the best option for shaping or moulding to fit a particular space. Brass also has high-temperature resistance and is a good choice for welding.
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Hose routing: straight or angled
When plumbing a race car's fuel system, the hose is the vital link that joins all the components together. The purpose of a hose is to get fluid from point A to point B, serving as the "liquid transfer system". The type of hose you choose will depend on the type of fluid being transferred. For example, PTFE hose has a wide range of fuel compatibility, while synthetic rubber hoses are not suitable for all fuel types and can cause contamination issues.
The routing of the hose, whether straight or angled, will depend on the specific application and space constraints. Straight hoses are simpler and more straightforward, but they may not always be feasible due to the layout of the car's engine and other components. Angled hoses, on the other hand, can navigate bends and twists and are useful in tight spaces. They can also help prevent kinks in the hose, which can cause flow restrictions. Angled hoses are available in various angles, such as 45, 90, 135, and 180 degrees, offering flexibility in installation.
It is important to consider the pressure specifications and material compatibility when selecting a hose. Inferior hoses may be sensitive to certain fuels, leading to decomposition and contamination. High-pressure applications, such as fuel injection, typically require hoses with PTFE cores, which can withstand higher pressures. The fittings used in conjunction with the hoses are also crucial. Adapter fittings with straight threads, for instance, require O-ring seals to prevent leakage, while tapered threads use sealing compounds or Teflon tape.
Additionally, the length of the hose should be sufficient to reach all the necessary components with some flexibility. A simple diagram of the intended setup can help visualize the required length and potential issues. It is also essential to secure the fuel hose properly to prevent movement and protect it from heat. Overall, the choice between straight and angled hoses depends on the specific requirements of the race car's fuel system, taking into account factors such as space constraints, pressure specifications, and compatibility with fluids and fittings.
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Fuel type: pump gas, E85, or racing fuel
The type of fuel used in a race car is an important consideration when plumbing a vehicle, as it will determine the type of fuel line required.
Pump Gas
Pump gas is a common choice for race cars, and it can be used with inexpensive plumbing components. However, it's important to consider long-term goals when selecting plumbing components. For example, if you decide to switch to a different type of fuel, such as E85, you may need to replace your fuel lines if they are not compatible with the new fuel.
E85
E85 is a high-octane fuel that can provide increased horsepower and a smoother power delivery. However, it requires a larger fuel volume, which means upgrading your fuel system, including the fuel lines. E85-specific fuel lines are typically made of synthetic rubber and are rated for carbureted engines.
Racing Fuel
Racing fuel is designed to deliver high power outputs and improved combustion characteristics. It contains specialized additives and oxygenates that enhance performance and reliability under extreme racing conditions. However, these additives may not be compatible with the fuel system components of regular cars. When using racing fuel, it is important to use approved fuel containers and to regularly inspect them for damage or leaks. Additionally, a fuel management strategy should be developed to monitor fuel consumption and estimate refueling needs.
In summary, the type of fuel line required for a race car depends on the type of fuel being used. It is important to consider the compatibility of the fuel line with the fuel type, as well as the long-term goals for the vehicle. Consulting the rule book for your track or sanctioning body is also recommended to ensure compliance with any regulations.
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Frequently asked questions
The amount of fuel line needed to plumb a race car depends on the make and model of the car, as well as the type of fuel system being used. It's recommended to draw a simple diagram of where you intend to mount the various components, including the fuel tank, pump, and engine. This will help you visualise the required length of the fuel line.
It's important to select a fuel line that is compatible with the type of fuel being used and the specific requirements of the fuel system. Metal lines, typically made from stainless steel, aluminium, or coated steel tube, are commonly used in race cars as they hold up better than soft materials. However, metal lines can be difficult to fabricate, so rubber fuel hoses, which are easier to install, are also an option. It's crucial to ensure that the chosen material is compatible with the fuel type to prevent decomposition and contamination.
When installing fuel lines, it's important to avoid sources of heat, such as the exhaust, as well as any moving parts or sharp edges that could damage the hose. The hose ends should be used to route the hose, utilising different angle hose ends to achieve a straight line from point A to point B. This ensures the safest and most efficient transfer of fuel. It's also crucial to consider the pressure specifications of the fuel system and choose a hose that can handle the required pressure.
