Rajan Wilcox
Connecting metal fuel lines can be a tricky process, and there are several ways to do it. One common method is to use a pushlok fastener with an AN nut and sleeve, mating it to the pushlock fitting. Another approach is to use a compression fitting, but this is not legal for fuel lines in some places, and there may be safety concerns. Flaring the tubing or using a double flare union are also options, but it's important to ensure the connection is secure to prevent leaks.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Connecting steel fuel line to rubber fuel hose | Slip the hose over the pipe and use fuel line clamps; use a pushlok fastener with an AN nut and sleeve; use the pushing method with two "fuel injection" clamps |
| Joining two 3/16" hard fuel lines | Double flare union; use a swedging tool and a MAP gas torch, Oaty flux Oaty solder; braze with a brazing rod and an acetylene torch |
| Fuel injection lines | Dorman nylon lines with GM style fittings; 3/8" supply and 5/16" return |
| Connecting fuel hose to stainless tube | Barb the steel tubing first, then slip the hose over the barbed end and clamp; flare the end of the tube with a flare tool, then slip the hose over the flare and clamp |
| Splicing metal fuel line | Compression fittings if the OD of the tube is clean; double flare tool |
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What You'll Learn
Using clamps to connect metal fuel lines and rubber hoses
When connecting metal fuel lines and rubber hoses, clamps are a commonly used method. However, it's important to choose the right type of clamp to ensure safety and effectiveness. Here are some detailed instructions and considerations for using clamps to make these connections:
First, it's important to understand the basic procedure for connecting metal fuel lines and rubber hoses using clamps. Typically, you would start by slipping the rubber hose over the metal pipe. Then, you would secure the connection using fuel line clamps. These clamps are designed specifically for fuel line applications and are similar to heater hose clamps, but they are adjusted to avoid damaging the rubber hose.
When selecting the clamps, it is highly recommended to avoid using worm gear clamps or standard nylon cable ties. Worm gear clamps can cut into the rubber hose, compromising its integrity. Instead, opt for specialised fuel injection clamps or clamps specifically designed for fuel hoses, such as Oetiker clamps. These clamps provide equal clamping force around the entire hose, reducing the risk of leaks.
To ensure a secure connection, it is often advised to double clamp the hose with two fuel injection clamps. This provides added security and helps prevent leaks, especially in high-pressure applications. Additionally, consider flaring the end of the metal fuel line before clamping to further enhance the connection's safety.
In some cases, you may need to use a pushlok fastener of the proper size to match the hard line. This method involves flaring the line, using an AN nut and sleeve, and then mating it to the pushlock fitting. This approach provides a more permanent and secure connection compared to simply clamping the hose over the pipe.
When working with fuel lines, it is crucial to prioritise safety. Always ensure that the connections are secure and leak-free to prevent potential hazards. If you are unsure about the correct clamps or connection method, it is recommended to consult a professional or seek advice from a trusted source.
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Using flared ends to connect metal fuel lines and rubber hoses
Flaring a fuel line for a rubber hose is an important step in preparing your vehicle for maintenance or repairs. It involves creating a cone or funnel shape at the end of a metal pipe to securely attach to a fitting or hose. This is especially important in automotive applications where fuel lines have to hold pressure and not leak.
To begin, you will need a flare tool that matches the size of your fuel line. Place the fuel line into the tool and tighten it to hold the line in place. A double flaring kit or a bubble flaring kit can be used to form the flared end of the line. It is important to make sure that the flaring tool matches the size of the fuel line to create a secure fit. You can also use a regular flaring tool and a double flare adapter to create a "bubble" on the end of the tube.
Next, use a tubing cutter to cut the end of the fuel line at a 90-degree angle. This will ensure that the flare is formed properly. The cut should be straight and clean. A crooked cut will make a lousy flare. After cutting, use a deburring tool to smooth out the inside and outside edges of the tube. This step is crucial to prevent the tube from cracking when it is flared.
Now, insert the tube into the appropriate-sized die in the flaring tool. The amount of tube sticking out should be equal to the thickness of the tubing, as this determines the flare size. Slowly turn the tool handle to shape the end of the line. Once the flaring is complete, remove the line from the tool and attach the rubber hose to the flared end. The flare should create a tight fit inside the hose, providing a secure connection. Use a high-quality clamp to secure the hose in place.
It is important to note that different applications require different flares. For most automotive fuel lines, a 45-degree inverted flare is standard. Using the wrong flare can result in poor connections and potential fuel leaks. Additionally, when selecting a rubber hose, ensure it meets the necessary SAE standards for your application.
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Using compression fittings to splice metal fuel lines
Compression fittings can be used to splice metal fuel lines, although they are not recommended for high-pressure applications. They are commonly used as a repair solution for fuel lines prone to rust.
To use compression fittings, the outside diameter (OD) of the tube must be clean. The mating steel line should be rust-free to ensure a long-lasting, leak-free connection. It is important to note that common brass compression fittings are designed for soft copper lines, and moving the fitting after sealing may cause leaks.
For fuel lines, it is recommended to use carbon steel or stainless steel fittings, especially when exposed to alcohol fuels, as brass and bronze fittings have poor resistance to vibration and can lose their tightness over time.
When splicing metal fuel lines, it is crucial to ensure a positive seal to prevent leaks. One method is to double flare the lines and use an adapter to connect the flared ends. This technique is commonly used in racing and is known for its reliability.
Additionally, when connecting metal fuel lines to rubber hoses, it is important to use the correct clamps and fasteners to prevent leaks and ensure safety.
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Using double flare unions to connect two hard fuel lines
Using double flare unions is a common method to connect two hard fuel lines. This method is often used for fuel injection lines, and it is rated for over 1200 psi. It is also possible to use a single flare, but a double flare is considered more secure.
To create a double flare, you will need a flaring tool, a nut, and a sleeve. First, install the nut and sleeve over the line, then use the flaring tool to create the flare. The sleeve sits against the back of the flare, and the nut holds everything tight. It is important to ensure that the mating steel line is rust-free for a long-lasting, leak-free connection.
You can purchase a flaring tool from hardware stores or auto parts stores. A Rigid 37-degree flaring tool is a good option, although it is more expensive than other tools. Some users have reported success with cheaper alternatives, but the quality of the flare may not be as good.
While double flaring can be challenging, especially with shorter lines, it is a reliable method to connect two hard fuel lines.
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Using nylon lines and GM-style fittings for fuel injection lines
When it comes to fuel injection lines, nylon lines and GM-style fittings are a recommended combination. This setup offers several advantages, including durability, flexibility, and resistance to fuel additives that can degrade standard rubber hoses. Here's a detailed guide on using nylon lines and GM-style fittings for fuel injection lines.
Selecting the Right Components:
Firstly, ensure you have the correct sizes for your fuel injection lines. Typically, you'll need a 3/8" supply line and a 5/16" return line. Dorman nylon lines are a popular choice and can be sourced from auto parts stores or online retailers. GM-style fittings, which are also known as GM bubble fittings, can often be found at local junkyards at reasonable prices.
Installing the Fittings:
Installing the GM-style fittings onto the nylon lines is a crucial step. There are several methods to achieve this:
- Dorman Tool: Dorman offers a specialised tool designed for inserting the GM fittings into the nylon lines. While this tool can be expensive, it guarantees a secure connection.
- Boiling Water or Heat Gun: Some people have suggested using boiling water to soften the nylon line before inserting the fitting. Others recommend using a heat gun to heat the line, but exercise caution when working around fuel vapours.
- Hair Dryer Method: Another approach is to use a hair dryer to heat the nylon line. Create a 3" aluminium foil tube to trap the heat around the line. Be careful not to melt the line, and aim for a temperature of around 250 degrees.
- Compression Fittings: If you don't want to use heat, you can opt for compression fittings. Push the nylon line firmly onto the fitting using hydraulic force and suitable fixtures to hold both components in place.
Additional Considerations:
When working with fuel injection lines, it's essential to prioritise safety. Always work in a well-ventilated area and take the necessary precautions when handling flammable liquids. Additionally, ensure that your fuel lines are securely clamped to prevent leaks. It's worth noting that nylon lines may not be ideal for custom applications, as they don't bend easily and can be challenging to work around.
By following these guidelines and selecting the appropriate tools and fittings, you can successfully connect nylon lines with GM-style fittings for your fuel injection system. Remember to consult experts or professionals if you have any doubts or encounter specific challenges during the installation process.
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Frequently asked questions
You can slip the hose over the pipe and use fuel line clamps. However, some people consider this unsafe. A safer method is to use a pushlok fastener of the proper size to match the hard line. You can also use the method of pushing the hose on the hard line and using two "fuel injection" clamps.
You can use a double flare union to join the two lines. First, flare the lines, then get two tube nuts and an AN(JIC) union to match. You can also use a swedging tool and put one line inside the other and sweat it like a copper water pipe.
The steel tubing has to be barbed first. If you slip rubber hose over straight tubing, the hose will come off no matter how hard you clamp it. The correct method is to barb the end of the steel tube, slip the hose over the barbed end, then clamp past the barb.
Yes, you can use compression fittings if the outside diameter of the tube is clean. However, keep in mind that compression fittings are not legal for fuel and brake lines in Canada and may not be ideal for cold/heat fluctuations.
