Katerina Swanson
Building a custom fuel line can be a rewarding experience, offering a sense of gratification and personalisation for your vehicle. The process involves fabricating replacement parts, specifically bending and flaring tubes to create fuel lines that meet your desired specifications. This allows for custom routing of the lines to achieve a unique setup. There are various methods and tools available for constructing fuel lines, with options to suit different budgets. It is important to consider the materials used, such as stainless steel, which is more durable and resistant to corrosion but also harder to work with. Safety is a key factor, especially when dealing with high-pressure injection systems, and proper sealing techniques, such as double flares, are crucial to prevent leaks.
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What You'll Learn
Using a hacksaw
Before you begin, ensure you have the right safety equipment. Some people recommend taping up the area you are going to cut to minimize the chance of a spark. It is also a good idea to have someone standing by with a fire extinguisher.
If you are cutting a fuel line in place, you should use a greased fine-tooth hacksaw blade. You should also use compression fittings, not rubber hoses when you put it back together. It is also recommended to do this outdoors with plenty of ventilation.
To cut the line, slowly increase pressure on the hacksaw blade and rotate the cutter in a back-and-forth motion for 360 degrees until the line severs. You can also use a junior hacksaw blade wrapped in a cloth to cut through.
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Bending and flaring
When fabricating lines, it is important to take your time and get it right. Cockeyed and incomplete flares can lead to time-consuming corrections and leakage. Stainless steel is harder to work with than galvanized steel, so extra care must be taken when bending it. It is also more challenging to get a good double flare from stainless steel. Some professionals suggest using a hacksaw instead of a tubing cutter, as the latter will work-harden stainless, making it tougher to get a proper flare.
When flaring brake and fuel lines, it is recommended to use a lubricant at the flaring head and line end. For fuel lines, use a low-viscosity engine oil or WD-40 as a lubricant. It is mandatory to apply a double flare to every line end and fitting. Fittings with AN connections get a 37-degree flare, while OEM applications use a standard 45-degree flare.
When bending stainless steel tubing, it is important to use the correct wall thickness. A thickness of 0.035" is recommended for 3/8" and 1/2" tubes, as anything thinner will tend to flatten and wrinkle on the inside bends, and anything thicker will be very hard to bend and flare.
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Choosing the right material
Cost and Durability
The cost of the fuel line material can vary significantly, depending on the type and quality. For instance, the Earl's UltraPro hose, which is made of PTFE (polytetrafluoroethylene) with a carbon impregnation, is quite expensive. However, it offers excellent durability and is designed to last the lifetime of your vehicle. On the other hand, rubber-lined braided hoses, such as the Vapor Guard hose, are more affordable but may not withstand extreme heat or long-term use as effectively as PTFE hoses.
Compatibility and Safety
It is essential to choose a material that is compatible with the type of fuel and additives used in your vehicle. For example, rubber fuel lines have been known to deteriorate prematurely due to the addition of ethanol and other additives in modern pump gasoline. PTFE, on the other hand, is highly resistant to the degenerative effects of fuel and creates an effective vapor barrier, preventing fuel vapors from leaking.
Flexibility and Installation
The flexibility of the fuel line material is an important consideration, especially when routing the lines in tight spaces. PTFE hoses, while offering superior resistance to fuel vapors, are less flexible than standard braided or rubber hoses. Rubber fuel lines, on the other hand, are easy to install and can be connected using standard barbed fittings and hose clamps. However, they may not be suitable for certain high-performance applications and can degrade over time when exposed to fuel.
Conductivity and Static Electricity
In some cases, the conductivity of the fuel line material may be a concern. For instance, non-carbon-infused PTFE is susceptible to static electricity discharge. However, by impregnating PTFE with carbon, as seen in Earl's latest fuel lines, this issue can be mitigated, making the material conductive and safer for fuel transfer.
Compliance with Regulations
When choosing a fuel line material, it is important to ensure that it complies with safety regulations and any specific rules for your vehicle's intended use. For example, if you plan to race your vehicle, refer to the rule book for your track or sanctioning body to select the appropriate material. Additionally, certain materials may be prohibited or restricted in length, such as non-covered rubber fuel hoses, due to safety regulations.
In summary, selecting the right material for your fuel line involves considering factors such as cost, durability, compatibility, safety, flexibility, conductivity, and compliance with regulations. By carefully evaluating these factors, you can choose the most suitable material for your vehicle's fuel line, ensuring optimal performance and safety.
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Fitting and sealing
When connecting a threaded port to a hose barb connection, it is recommended to use two hose clamps at each connection point of the fuel line over the hose barb. These clamps should be made of marine-grade stainless steel and provide even sealing tension. Using two clamps requires a hose barb long enough to accommodate both. It is important to consult a professional or have your work inspected to ensure there are no fuel leak hazards.
The type of fuel hose you choose depends on its location. If it is above the deck, it is in the open, such as an outboard engine connected to an above-deck tank. Below the deck includes not only below-deck areas but also hoses running through confined compartments. For below-deck installations, it is recommended to use A1 fuel hose, which offers the highest fire resistance and the least permeability. B-type fuel hoses are more permeable and suitable for less volatile fuels like diesel.
When it comes to sealing fuel fittings, there are various options available. Tapered NPT threads, commonly found in standard plumbing fittings, typically require sealants. You can use pipe thread sealant or liquid thread sealant. It is important to know the thread type of the component you are purchasing and match it with the corresponding thread type. For example, most fuel filters, pumps, and tank connections have female NPT or NPTF ports, requiring a male hose barb fitting. Brass or stainless steel are commonly used for these components.
While some backyard mechanics suggest using Teflon tape, it is not recommended due to the risk of clogging. Instead, liquid or paste-type sealants are preferred as they are less likely to break free and cause issues downstream. For gasoline systems, Aviation Form-a-gasket Number 3 is a suitable option. Additionally, specific fittings like the convoluted PTFE hose, also known as UltraPro, require a sealing ferrule and a precise assembly procedure.
It is important to note that over-tightening fuel fittings can lead to leaks. Fittings should be tightened snugly, and if leaks occur, it is recommended to find the root cause instead of relying solely on sealants. Flared fittings, such as 37-degree AN or 45-degree double flare, typically do not require thread sealant as the flare provides the seal when properly tightened. However, threaded fittings without a flare, like NPT fittings, are recommended to have thread sealant applied to specific threads.
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Testing and maintenance
Testing Fuel Pressure
Fuel pressure issues can cause significant performance problems and even safety hazards. To test your vehicle's fuel pressure levels, you will need a fuel pressure test kit, which typically consists of a gauge and a fuel hose. First, open the hood of your vehicle and locate the fuel pump test point, usually found near the fuel injectors. Remove the cap from the test point and attach the fuel hose. Before taking a reading, ensure that you bleed the fuel pressure gauge to release any trapped air.
Ask an assistant to activate the ignition, then carefully monitor the fuel pressure level displayed on the gauge. Take note of the pressure readings, then compare them to the specifications outlined in your vehicle's owner's manual. Ideal fuel pressure levels typically range from 30-80 PSI, but the optimal range may vary depending on your vehicle's engine. If your vehicle's fuel pressure is outside the specified range, there may be an issue with the fuel pump, fuel filter, or fuel return line.
Maintaining and Repairing a Fuel Line
Fuel lines, especially older ones, are susceptible to rotting and degradation over time. If you suspect issues with your fuel line, it is essential to address them promptly to prevent leaks and maintain optimal vehicle performance. In some cases, you may need to replace the entire steel line. However, if you are only dealing with a small section of damage, you can splice in a new line using compression fittings. These fittings are suitable for low-pressure steel lines but may not be recommended for high-pressure lines.
When working with fuel lines, always exercise extreme caution. Fuel vapors are highly flammable, so ensure you work in a well-ventilated area and have a fire extinguisher nearby. Additionally, be cautious when handling rusty or corroded lines, as the rough surface can cause seepage when connected to a rubber hose. Always flare the ends of the steel line to ensure a secure connection, and consider using fuel injection clamps for added security.
If you are uncomfortable or unfamiliar with fuel line maintenance, it is best to consult a competent mechanic. They will have the knowledge and tools to safely and effectively address any issues with your fuel line.
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Frequently asked questions
The best material for a fuel line is a carbon-impregnated PTFE hose, which is conductive and prevents static electricity discharge. This material is also used in new OE production cars as it is impervious to all fuels and additives.
The safest type of fuel line is a steel line. Steel lines are safer than rubber lines because they are less likely to crack and leak raw fuel onto a hot exhaust manifold.
You will need a flaring tool, a hacksaw, a tubing cutter, a vise with soft jaws, and a good-quality bender.
The easiest way to build a fuel line is to use AN fittings. First, wrap blue painter's tape around the braided hose and cut through it with a hacksaw. Then, install the AN socket-side fitting and lubricate the threads. Finally, secure the socket-side of the fitting with a wrench.
