Mercedes Mullins
Flaring a fuel line is an essential step in creating custom brake and fuel lines that accept proper fittings. There are several methods for flaring a fuel line, including using a turret-style line flaring tool, a hydraulic flaring kit, or a double bubble flare tool. Some people also choose to use a hose barb or two clamps to splice coolant hoses or fuel lines. When deciding between a single or double flare, it is important to consider the type of tubing being used, as double flares can cause cracking in aluminum tubing.
Characteristics and Values Table for Flaring a Fuel Line
| Characteristics | Values |
|---|---|
| Tools | Hydraulic flaring kit, tubing cutter, turret-style line flaring tool, double bubble flare tool |
| Materials | Steel, stainless steel, copper, aluminium |
| Techniques | Single flare, double flare, bubble flare |
| Cost | $300-$400 for a decent double bubble flare tool |
| Ease | Difficult to work with stainless steel, easy to damage internal braid when fitting a hose over a large flare |
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What You'll Learn
Using a flaring tool
The first step in using a flaring tool is to cut your line to the proper length. You can use a hacksaw or cutting disc, but a more precise approach is to use a tubing cutter, which gently cuts into the line. Once you have your line cut, you will need to bend it to match your template. For this step, you will need a tube bender.
With your line cut and bent to your desired specifications, you can now flare the ends. There are a few different methods for flaring, depending on your preferences and the type of line you are working with. The most common style of flare used in automotive hard lines is the 45-degree inverted flare, which is created in a two-step process, resulting in a double-walled flare seat. This type of flare does not require a tube sleeve or flare seat support due to the extra wall thickness. If you are using AN fittings, you will need to create a 37-degree flare, which requires a tube sleeve to support the back of the flare and is secured with a female threaded tube nut.
When flaring brake and fuel lines, it is recommended to 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.
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Single vs double flares
Single flares are usually used for fuel lines. A flaring tool is used to simply make a "funnel" out of the end of the tubing so it will fit with the male flare nut. Copper and aluminium tubing is usually only single-flared as it tends to split. Single flares are also used for low-pressure applications.
Double flares, on the other hand, are more difficult to do correctly. To make a double flare, take a single flare end and fold it back on itself. Double flares are used for high-pressure connections such as brake lines. They are stronger and harder to do than single flares. Double flares are also used for steel lines.
Some people have recommended using double flares for fuel lines for durability, as single flares are prone to falling out. However, others have noted that single flares are fine for fuel lines, as long as they are not taken on and off many times.
To make a flare on a fuel line, you will need a flaring tool. These can be purchased from auto stores or hydraulic line fabrication shops. If you are working with stainless steel, be aware that it is more difficult to work with than steel.
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Types of fuel lines
Fuel lines can be made from many different materials. Metal is the best material for fuel lines, but it can be difficult to fabricate. Metal lines are usually made from stainless, aluminum, or coated steel tubes. Stainless steel hard lines are available pre-bent and can be modified if needed. They are also available in seamless aluminum, which is a cost-effective choice for high and low-pressure fuel lines.
Rubber fuel hoses are easy to install and are typically connected using standard barbed fittings and fuel line hose clamps. They must be rated for fuel or meet SAE grades. Carburetor-rated rubber hoses should only be used in limited runs up to 50 psi. Fuel injection-rated hoses can handle up to 100 psi. In-tank rubber hoses are also available, such as the J30R12 hose, which is Teflon-lined.
Nylon tubing is another option for fuel lines. It is a popular choice for manufacturers due to its ability to reduce evaporative emissions and its smooth internal surface. Nylon tube is available in rigid and flexible convoluted tubes, with an operating pressure of 250 psi and a burst pressure of up to 1000 psi. Braided hose is a type of rubber hose with a braided stainless or nylon exterior that uses AN hose ends to connect to the fuel system. PTFE-lined braided hoses are the best soft hoses and have similar connections but require special fittings.
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Preventing damage to fuel lines
To prevent damage to fuel lines, it is important to regularly check and replace any defective lines. This is especially important if you have a boat or vehicle that uses diesel fuel, as untreated diesel fuel can have a corrosive effect on metal components, including fuel lines, given the right conditions and enough time. Copper, zinc, and aluminum components are particularly susceptible to corrosion from diesel fuel, so it is recommended to avoid using these materials if possible and to use anti-corrosion additives.
Another way to prevent damage to fuel lines is to properly seal the fuel line threads. Leaks can occur when the threads are not properly sealed, leading to performance issues and safety hazards. There are several types of sealants that can be used, including Teflon tape, pipe thread compound, and anaerobic sealants. It is important to identify the type of threads you are dealing with (tapered or straight) and to choose the appropriate sealant for your specific application. Thread lockers and thread inserts can also be used to prevent loosening and ensure a leak-proof seal.
Before sealing the fuel line threads, it is crucial to clean the threads of both fittings and to test for leaks after sealing. This can be done by connecting the fuel line to the fuel system, turning on the fuel pump, and inspecting the fuel line connections for any signs of leaks, such as drips or bubbles. If a leak is detected, the fittings should be tightened slightly with a wrench, but it is important to avoid overtightening. If the leak persists, the faulty fitting may need to be replaced.
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Finding the right tools
Flaring a fuel line is an essential step in making custom fuel lines to ensure proper fittings. There are a few ways to create flares on fuel lines, and the right tools will depend on the type of flare you want to create.
A single flare is the most common type of flare and can be made using a standard brake line flare tool or a flaring tool for tubing. These tools are widely available and can be purchased online or at most auto shops. If you're looking for a cheaper option, you may be able to find a rental kit for single flares, which can cost as little as $13.
Double flares, on the other hand, require a specialised tool known as a double bubble flare tool. These tools are more expensive, typically costing around $300-$400. Due to their higher cost, it may be more practical to search for a local auto shop that has one available or a shop that builds hydraulic lines for commercial equipment.
Additionally, consider the type of material you will be working with. For example, stainless steel is more difficult to work with than steel, and special machines may be required for certain materials. If you're unsure, it may be helpful to consult with a professional or a specialist shop that deals with hydraulic lines and related work.
Finally, it's important to note that the type of flare you choose will depend on the specific application and the pressure requirements of your fuel system. For higher-pressure systems, a double flare may be necessary, while a single flare is often adequate for most other applications.
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Frequently asked questions
You can use a turret-style line flaring tool, a double bubble flare tool, or a hydraulic flaring kit.
Flaring the end of a line is essential when making custom fuel lines to accept proper fittings. You can do a single flare if you are concerned about cracking with a double flare.
If you don't have the tools to flare your fuel line, you can try finding a local auto shop or a shop that builds hydraulic lines for commercial equipment.
