Sylvie Willis
Building your own push-on fuel lines can be a gratifying experience, allowing you to personalize your car and ensure the lines are routed exactly where you want them. The process involves tube bending and flaring, which can be done in your home garage with the right tools and materials. It is important to take your time and get it right to avoid issues with cockeyed and incomplete flares, which can lead to time-consuming corrections and leakage. The type of material you choose for your fuel lines is crucial, with options like stainless steel known for its durability and resistance to corrosion but requiring extra care during the bending and flaring process. Other options include plastic-coated steel lines, which are easier to bend but come at a higher cost. When it comes to fittings, AN fittings are a popular choice, offering an open-source fluid transfer technology. Overall, building your own push-on fuel lines can be a rewarding project, but it requires careful planning, the right tools, and a good understanding of the process to ensure a successful outcome.
Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Materials | PTFE (Teflon-like material impregnated with carbon), stainless steel, galvanized steel, plastic-coated steel |
| Tools | Tube bending and flaring tools, hacksaw, tubing cutter, double-flaring tools, benders, flaring tool, hydraulic flare tool |
| Techniques | Tube bending and flaring, using a hacksaw instead of a tubing cutter to prevent work-hardening, using a lubricant at the flaring head and line end, ensuring line ends are free of burrs and imperfections |
| Cost | Varies depending on materials and tools; PTFE hose with fittings can be expensive, with a 20-foot length of Ultra-Pro hose costing over $180 |
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What You'll Learn
Using a hacksaw
When it comes to using a hacksaw to build your own push-on fuel lines, there are several important steps to follow. Firstly, it is recommended to use a hacksaw with at least 32 teeth per inch. Before cutting, wrap blue painter's tape around the braided hose where you intend to make the cut. This will help you mark the exact location of the cut and also prevent the braid from fraying. Ensure the cut is straight and perpendicular to the hose end by guiding the hacksaw along the edge of a vise with soft jaws.
After cutting the hose to the desired length, the next step is to install the AN socket-side fitting. Remove the hose from the soft jaws and position the fitting as shown. Take away the blue tape from the hose end and insert the hose into the socket, using a small flat-head screwdriver to help guide it in place if needed. It is important to leave a 1/16-inch gap between the end of the hose and the first thread of the fitting.
Mark the outside of the hose at the base of the socket with a reference point, which will help you identify any movement of the hose during the tightening process. Install the cutter-side fitting into the soft jaws and lubricate the threads and male end of the fitting with oil or antiseize. Finally, hold the hose securely and push the hose and socket-side fitting onto the cutter-side fitting in the vise, ensuring a secure connection.
It is worth noting that while a hacksaw is a viable option, some professionals suggest using a tubing cutter instead. This is because a tubing cutter provides a smoother cut and reduces the risk of work-hardening the stainless steel, making it easier to achieve a proper flare. However, when using a tubing cutter, it is crucial to ensure that the line ends are free of any burrs or imperfections that could compromise the integrity of the fuel line.
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Bending and flaring tools
There are a variety of bending tools available, from manual options like the Imperial Eastman and Ridgid to hydraulic options like the Eastwood Hydraulic Flare Tool. The Eastwood tool is particularly useful when you need to flare a line that is still connected to the car, as it can create a perfect flare without the need to remove holding clamps or take the line to a bench unit. It is slender and can manoeuvre in tight spaces, making it ideal for working around body panels.
Another factor to consider when choosing bending tools is your budget. Bending tools can range from simple and affordable options, such as a large socket or a metal tubing bender, to more expensive hydraulic options. It is worth noting that some tools may require additional equipment, such as a bench vise, to complete the job. Additionally, some tools may be more suitable for certain types of flares or tubing materials, so it is important to do your research and choose the right tools for your specific needs.
Flaring tools are equally important and are used to create the necessary flares at the ends of the fuel lines. It is mandatory to apply a double flare to every line end and fitting, and a 45-degree double flare is specifically required for brake and fuel lines. Flaring tools can vary in price and functionality, with some requiring one-hand operation while others require two hands and multiple physical motions to form a double flare. When flaring brake and fuel lines, it is recommended to use a lubricant at the flaring head and line end to ensure a smoother process.
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$69.99 $75.99
The importance of lubricants
Building your own push-on fuel lines can be a gratifying project, allowing you to personalize your car and ensure it functions optimally. When undertaking such a task, the importance of lubricants cannot be overstated. Lubricants are essential in reducing friction and abrasion, protecting metal surfaces, and improving overall performance.
The use of lubricants in fuel lines is crucial to ensure the smooth operation of your vehicle's fuel system. Lubricants, such as low-viscosity engine oil or WD-40, are applied during the flaring process of fuel lines. This helps to create a smooth and seamless flare, preventing leaks and ensuring a proper seal. Without lubrication, the flaring process can result in cockeyed and incomplete flares, leading to time-consuming corrections and potential fuel leakage.
Additionally, lubricants are vital in maintaining the efficiency and longevity of your engine. Motor oils, for example, are designed to coat the moving parts of your engine with a thin film of lubrication, protecting them from friction and wear. This is especially important for high-pressure injection systems, where the fuel lines are subjected to significant stress and pressure. Lubricants with higher viscosity levels, such as heavy-duty engine oils, are also available for specific applications like large construction vehicles. These thicker lubricants provide an even more resistant coating, capable of withstanding the demands of heavy-duty machinery.
The type of lubricant you choose for your fuel lines is also important. It is recommended to use a lubricant that is compatible with the medium your lines will carry. For fuel lines, this typically means using a lubricant that is fuel-proof and soluble in petrol. Common options include Vaseline, grease, or other household lubricants that are clean and soluble in petrol. It is important to avoid using soap as a lubricant in fuel injection systems, as it may cause issues.
Furthermore, lubricants play a crucial role in other automotive systems, such as the brakes. Brake fluid, for instance, is a type of hydraulic fluid that serves as a lubricant in your car's brake system. When you press the brake pedal, the brake fluid acts as a petroleum-based hydraulic fluid, transferring the pressure to close the brake caliper pistons on the rotor. This process ensures that your brakes function effectively and safely.
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Choosing the right materials
Metal Fuel Lines
Metal fuel lines, typically made from steel or aluminum, are known for their durability and compatibility with various fuel types. They are generally more expensive than rubber or braided fuel lines. Metal lines are often used in low-horsepower and low-pressure situations and are suitable for most fuel types. However, they can be challenging to bend and route, especially when compared to braided or rubber hoses.
Rubber Fuel Lines
Rubber fuel lines offer superior flexibility, making them ideal for tight spaces. They are generally less expensive than metal or braided lines. However, their compatibility is limited as they may not be suitable for all fuel types and chemicals. Some vehicles use rubber fuel hoses to connect the fuel line to the fuel pump or carburetor.
Braided Fuel Lines
Braided fuel lines are made from a metal or synthetic fiber braid wrapped around a rubber core. They offer good flexibility, although not as much as rubber lines, and are generally considered an upgrade from traditional metal or rubber lines. Braided lines are compatible with a wide range of fuels but may have limited compatibility with certain chemicals. They utilize AN fittings, which provide a superior connection compared to traditional hose clamps.
PTFE-Lined Fuel Lines
PTFE (polytetrafluoroethylene) fuel lines have an inner layer of PTFE coated with a layer of braided stainless steel or other metal. PTFE-lined fuel lines are known for their flexibility and compatibility with a wide range of fuels and chemicals. However, they are typically more expensive than other types of fuel lines. The latest offerings from brands like Earl's include a carbon-impregnated PTFE hose, which further enhances its performance.
Other Materials
In addition to the primary materials mentioned above, other materials used in fuel lines include copper, nylon, and synthetic hoses. Copper hoses were commonly used in older vehicles and are easy to install, but they are bulky and expensive. Modern vehicles often use nylon or other plastic fuel lines, which are lightweight and do not rust but may melt at low temperatures. Synthetic hoses are used where flexibility is required, and they are compatible with a wide range of fuels and chemicals.
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Fitting and sealing
First, it is important to understand the different types of fuel lines and fittings available. There are four grades of fuel lines: A1, A2, B1, and B2. A1 fuel hose is the best choice for most applications as it offers the highest fire resistance and the least permeability. It is also suitable for both above and below-deck installations.
When it comes to fittings, there are several options. AN fittings, for example, require a 37-degree flare. It is mandatory to apply a double flare to every line end and fitting to ensure a secure connection. You can use a lubricant at the flaring head and line end to make the process smoother. For fuel lines, a low-viscosity engine oil or WD-40 can be used as a lubricant.
Additionally, you can use tube bending and flaring tools to create custom bends and flares in your fuel lines. These tools are available from various sources and are designed to fit different budgets. Stainless steel, for example, is a popular choice as it is highly durable and resistant to corrosion, but it is more challenging to work with than galvanized steel due to its hardness. When working with stainless steel, it is recommended to use a hacksaw instead of a tubing cutter to avoid work-hardening the material.
When fitting the fuel lines, it is important to ensure that the line ends are completely free of burrs and imperfections. This will help create a proper seal. You may also need to bend the lines to navigate around obstacles. In such cases, it is crucial to use good-quality benders to achieve the correct radius.
Finally, sealing the fuel lines is critical to prevent leaks and fires. The sealant you choose will depend on the type of fuel (diesel or gasoline) and the thread type of your fittings. NPT (National Pipe Taper) threads, for example, are common in fuel line components and typically require a sealant. You can use pipe thread sealants, such as Permatex, or Teflon tape or paste. However, it is important not to over-tighten the fittings, as this can stretch the threads and cause leaks. For marine applications, Rectorseal and Leak Lock are recommended by boaters.
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Frequently asked questions
The best material for a custom fuel line is a convoluted PTFE (polytetrafluoroethylene) fuel hose, which is similar to Teflon. This material is used in all new OE production cars as it is impervious to all fuels and additives. It also offers a near-perfect vapour barrier, preventing evaporation through the fuel line.
You will need a variety of tools, including a hacksaw, tubing cutter, tube bending and flaring tools, and a flaring lubricant. It is also recommended to get extra tubing to practice on.
First, measure the length of the fuel line needed, adding a few extra inches to account for mistakes. Then, cut the hose with a hacksaw, ensuring the cut is straight and perpendicular to the hose end. Next, use tube bending and flaring tools to bend and flare the tube to the desired shape. Finally, install the fittings and lubricate the threads and male end of the fitting with oil or antiseize.
