Ameer Randolph
In his article, 'How to Build a Fuel Line', Lars Grimsrud offers a comprehensive guide to constructing a fuel line for vintage vehicles. The article is part of a series of technical papers by Lars, which includes other automotive topics such as carburetor installation, ignition system primers, and brake replacements. Building a fuel line requires a range of tools, including tubing cutters, benders, and flaring tools, with Lars recommending specific brands and sizes to ensure the correct fit. The process involves careful measurements and precise assembly, with attention to the type of vehicle and its performance requirements, such as horsepower and fuel pressure.
| Characteristics | Values |
|---|---|
| Angle of AN type fittings | 37 degrees |
| Angle of other automotive fittings | 45 degrees |
| Angle of flares for brake and fuel lines | 45 degrees |
| Tools required | Double flaring tools, tubing cutter, tubing bender |
| Recommended tubing bender brands | Weatherhead, Imperial |
| Recommended tubing sizes | 3/16, 1/4, 5/16, 3/8 |
| Line fitting | Should be installed before flaring |
| Clamp type | Steel or Adel |
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What You'll Learn
The correct tools for the job
For tube bending, you can use a tubing bender, or fill the lines with fine sand to make them more malleable. A large socket can also be used for bending tubes, and can even achieve bends that a tubing bender cannot.
For flaring, you will need a flaring tool. Flares come in single or double varieties, and at angles of 37 or 45 degrees. The type of flare you use will depend on the type of vehicle you are working on. Aviation standards, for example, require a 37-degree flare, while automotive standards require a 45-degree flare.
To get the fittings seated after the lines are cut, you will need a 1/2" ferrule crimping tool.
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The importance of precise measurements
Building a fuel line is a highly customisable process, and precise measurements are critical to the success of the project. The measurements will determine the efficiency and safety of the fuel line, and ultimately, the vehicle.
Firstly, the correct tools are essential. A tubing cutter, for example, will work-harden stainless steel, making it harder to achieve a perfect flare. A hacksaw is a better option for cutting stainless steel, as it will not work-harden the metal. The correct tools will ensure the measurements are precise, and the job is done properly.
Secondly, the type of material used will determine the measurements and the process. For example, stainless steel is harder to work with than galvanized steel, and requires extra care when bending and flaring. Stainless steel is also more challenging to flare, and a good double flare is almost impossible to achieve. The measurements and process will differ depending on the material, and the correct measurements are vital to ensure the fuel line is safe and efficient.
Thirdly, the measurements will determine the efficiency of the fuel line. For example, the size of the fuel pump must be large enough to support the horsepower, but too much fuel flow can negatively impact the vehicle's performance. Precise measurements will ensure the fuel line is optimised for the vehicle's performance.
Finally, precise measurements will ensure the safety of the fuel line. For example, the fuel line must be installed before flaring, or the measurements will be thrown off, and the line may be too long or short. The line fitting must also be installed before flaring, or it will be forgotten. Accurate measurements will ensure the safety of the vehicle and its performance.
In conclusion, precise measurements are critical to the success of building a fuel line. The correct tools, materials, and processes must be used to ensure the measurements are accurate, and the fuel line is efficient and safe.
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The role of tube bending
Building a fuel line is a highly customisable process, and tube bending plays a crucial role in this. The ability to bend tubes allows for the routing of fuel lines to be tailored to individual needs and preferences. This is particularly useful when restoring older vehicles for which pre-bent lines may not be available.
Tube bending can be done using a variety of tools, including tubing benders and even a large socket or hacksaw in a pinch. The best tubing benders are made by Weatherhead or Imperial and are available at tool and plumbing supply houses. These tools allow for precise bends to be made, ensuring that the fuel line follows the desired path.
When bending tubes, it is important to consider the material being used. Stainless steel, for example, is harder than galvanized steel and requires extra care when bending and flaring. It is also more challenging to achieve a good double flare with stainless steel, and a hacksaw is often recommended over a tubing cutter to avoid work-hardening the material.
In addition to the tools used, the technique employed during tube bending is crucial. One important technique is to ensure that the line fitting is installed before performing the flare. This prevents issues with the flare and ensures a secure connection.
Overall, tube bending plays a central role in building a fuel line, allowing for customisation, convenience, and the ability to tailor the fuel line to specific vehicles or applications.
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Fitting the line
Firstly, it is important to select the right tools for the job. For bending the tubing, a tubing bender is recommended, with Weatherhead and Imperial being the preferred brands. In addition, a tubing cutter or a hacksaw can be used to cut the tubing to the desired length. If you are working with stainless steel tubing, a hacksaw is suggested as a tubing cutter can work-harden the material, making it harder to achieve a proper flare.
When it comes to flaring, you will need a flaring tool. The standard angle for flaring in the automotive industry is 45 degrees, so ensure you have the appropriate 45-degree flaring tool. If you are working on an aircraft, it is important to note that the aviation standard is 37 degrees, so be careful not to confuse the two.
Now, let's move on to the bending and flaring process. Start by measuring and marking the tubing to the desired length. Use your chosen cutting tool to cut the tubing, ensuring that the ends are free of burrs and imperfections. If you are using a tubing cutter, be aware that it may work-harden the tubing, especially if it is made of stainless steel.
Next, you can begin bending the tubing to the required shape. Take your time during this step to ensure the tubing bends accurately without kinks or creases. A tubing bender is ideal for this task, but if you are on a tight budget, a large socket can also be used for bending.
Once the tubing is bent to the desired shape, it's time to flare the ends. It is crucial to install the line fitting before flaring. Use your flaring tool to create a 45-degree double flare, which is mandatory for fuel lines. This will help ensure a secure and leak-proof connection.
Finally, you can install the fuel line into your vehicle, securing it with steel or Adel clamps to prevent any movement. Ensure that the fuel line is routed away from any heat or moving sources, such as driveshafts or exhaust pipes, to maintain its integrity and safety.
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Avoiding corrosion
While building a fuel line, it is important to take measures to prevent corrosion, which can lead to leaks and other issues. Here are some ways to avoid corrosion:
Use Appropriate Materials:
Choose materials that are compatible with the type of fuel you are using. For example, diesel fuel can have a corrosive effect on certain metallic components, such as copper, brass, and aluminum, if it comes in in contact with them for extended periods. Therefore, it is recommended to avoid using these metals in your fuel system if you are using diesel fuel. Instead, opt for materials that are known to be compatible and resistant to corrosion, such as stainless steel or Teflon®-like materials (PTFE).
Protect Against Chafing:
Chafing is a common issue with fuel lines, and it can lead to abrasion and fuel leaks. To prevent chafing, ensure that the fuel lines are properly secured and supported, especially where they pass through bulkheads or metal structures. Use rubber grommets to protect hoses and lines as they pass through these areas. Additionally, avoid running fuel lines close to electrical wiring, engine controls, or exhaust pipes, as this can also contribute to chafing.
Maintain and Inspect Regularly:
Regular maintenance and inspection of your fuel lines can help identify and address corrosion before it becomes a major issue. During annual inspections, carefully check the fuel lines by passing your fingers along their length to ensure they are not rubbing against anything. If you notice any signs of chafing or corrosion, take appropriate action, such as replacing or repairing the affected sections.
Use Anti-Corrosion Additives:
In some cases, you can use anti-corrosion additives in your fuel to help prevent corrosion. These additives can reduce the formation of gum and varnish, which can be caused by exposure to copper and zinc ions in the presence of water. However, be sure to choose additives that are compatible with your fuel type and follow the manufacturer's instructions for proper use.
Choose Quality Parts:
Opting for high-quality parts and materials for your fuel system can also help prevent corrosion. While it may be tempting to use surplus or used accessories to save costs, it is important to prioritize quality. Carefully scrutinize and test new and used parts before installation to ensure they meet the required standards and are less likely to corrode.
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Frequently asked questions
You will need a tubing cutter, a tubing bender, and a double flaring tool.
The flare should be a 45-degree double flare.
The fuel line is either 3/8 or 5/16ths, depending on the horsepower.
Weatherhead or Imperial make the best tubing benders, according to Lars.
