Sylvie Willis
Plastic fuel lines are used to run fuel from the tank to the engine. They can be made from materials such as nylon or rubber. When creating a sharp bend in a plastic fuel line, it can be challenging to avoid kinks. To form a bend without kinking, one method is to use a shaping mandrel or bendable forming tool that can be inserted into the tube and then bent to the desired shape. Another method is to heat the plastic tubing with boiling water or a hairdryer to soften it before bending.
Characteristics and Values of Forming Plastic Fuel Lines
| Characteristics | Values |
|---|---|
| Plastic Type | Nylon |
| Tools | Shaping mandrel or bendable forming tool, lead, cut-open soft drink bottle, boiling water, hair dryer, heat gun |
| Challenges | Sourcing hard plastic fuel lines, kinking during sharp bends |
| Alternatives | Rubber lines, Bundy-Flex copper lines |
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What You'll Learn
Using nylon fuel lines
Nylon fuel lines are a popular choice for those looking to install a fuel line in their vehicles. They are known for their durability and ability to withstand high temperatures. Here is a comprehensive guide on using nylon fuel lines for your vehicle.
First, you will need to gather the necessary materials and tools. This includes a roll of nylon tubing, such as the Dorman 800-072, which has a size of 3/8". You will also need appropriate fittings, a light lubricant (e.g. hydraulic jack oil), a line clamp from a brake line flaring kit, a caulking gun, and a sharp cutting tool like a single-edge razor blade.
Once you have the required materials, start by making a clean cut at the end of the tubing. Insert this cut end through the caulking gun, and then place the tubing in the flaring tool clamp, ensuring that you select the correct hole size for your tubing. It is important to leave only enough tubing length to fit onto the fitting. Clamp the tubing tightly, but hand-tight is sufficient; it won't slip.
When it comes to joining the fittings, there are a few methods you can consider. One approach is to heat the brass fitting in boiling water and then install it while it's still warm. This prevents the fitting from rapidly cooling and shrinking, which can make it challenging to get the fitting seated properly. Alternatively, you can use a hairdryer to heat the plastic line directly, being cautious not to exceed temperatures of around 250 degrees.
Another method for shaping nylon fuel lines involves creating a shaping mandrel or a bendable forming tool. Lead is an excellent material for this purpose as it can be easily shaped and will retain its form. You can insert this lead tool into the tubing and then bend it to the desired shape. To set the shape, place the tubing in a cut-open soft drink bottle, pour in boiling water, and let it cool. Once the water has cooled, remove the lead tool, and your nylon fuel line will retain its new shape.
Nylon fuel lines offer a durable and reliable option for your vehicle's fuel system. By following these steps and choosing the appropriate tools and fittings, you can successfully install and shape nylon fuel lines to meet your needs.
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Splicing into hard plastic fuel lines
Prepare the Materials and Tools:
Firstly, gather the necessary materials and tools for the splicing process. You will need items such as hose barb fittings, a heat gun or boiling water setup, fuel injection hose, fuel injection clamps, rubber lines, and metal barbed fittings. These items can be sourced from auto parts stores or online retailers.
Heating the Plastic Lines:
Before splicing, it is crucial to soften the hard plastic lines to insert the fittings securely. This can be done by carefully applying heat to the ends of the plastic lines. Use a heat gun or, for more even heating, place the ends in boiling water. Be cautious to avoid burning the plastic.
Inserting the Hose Barb Fittings:
Once the plastic is softened, quickly insert the hose barb fittings into the heated ends of the plastic lines. Work with precision and speed as the plastic will start to harden again. A drop of motor oil can also be applied to make pressing the fittings into the plastic lines easier.
Connecting the Fuel Lines:
After the hose barb fittings are securely in place, you can connect the fuel lines. If you're working with high-pressure fuel lines, consider using rubber lines that can withstand the pressure. Secure the connections with small hose clamps to prevent leaks.
Testing and Finalizing:
Before finalizing the splicing, ensure all connections are secure and there are no signs of leaks. Test the system and check for any fuel leaks or abnormalities. If necessary, adjust the clamps or fittings to ensure a tight seal.
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Using a hair dryer to heat plastic lines
Using a hair dryer to heat plastic fuel lines is possible, but it may not be the most efficient or effective method. While the heat produced by a hair dryer can technically shrink plastic film, it may not be the best tool for the job due to potential issues with tearing, inconsistent shrinking, and temperature control.
If you decide to use a hair dryer to heat plastic fuel lines, there are a few things to keep in mind. First, be cautious and aware of your surroundings, as you are working with flammable materials. Always ensure the area is well-ventilated and that there are no sources of ignition nearby.
To get started, you can create a makeshift heat tunnel by making a tube from aluminium foil. This will help trap the heat from the hair dryer around the plastic line. Be careful not to melt the plastic line, and try to maintain a temperature of around 250 degrees or slightly above.
Keep in mind that heating the plastic line with a hair dryer may not be sufficient to make it soft enough to work with. You may need to combine this method with other techniques, such as soaking the line in boiling water, to achieve the desired flexibility. Additionally, consider using a heat gun instead of a hair dryer, as it is a professional tool specifically designed for packaging and can provide more consistent results.
Overall, while it is possible to use a hair dryer to heat plastic fuel lines, there are safer, more effective, and more efficient methods available. Always prioritize your safety and use your best judgment when working with flammable materials and heat sources.
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Creating a shaping mandrel or bendable forming tool
To create a shaping mandrel, you can use lead, which can be easily shaped into the desired form and will retain its shape. Lead can be melted and poured into grooves or seams to create the necessary shape. Alternatively, you can use a piece of tubing that is folded double to achieve the desired diameter. This tubing can then be inserted into the fuel line and bent to the required shape.
To set the shape, the lead or tubing can be placed inside the fuel line and heated. One way to do this is by placing the assembly in a cut-open soft drink bottle and pouring in boiling water. Allow the assembly to sit in the boiling water until the water cools. As the water cools, the plastic fuel line will retain its shape due to the heat.
It is important to note that when fabricating fuel lines, it is crucial to take your time and get it right. Improperly formed fuel lines can lead to issues such as leakage. Tube bending and flaring tools are available from various sources, including companies like Harbor Freight Tools and The Eastwood Company, offering options for different budgets.
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Using rubber lines vs. plastic lines
When it comes to choosing between rubber and plastic fuel lines, there are several factors to consider. Both materials are suitable for petrol, diesel, and oil transmission, but external factors like pressure, temperature, longevity, permeability, durability, and cost can impact which type of fuel hose is best for your needs.
PVC, a type of plastic, is suitable for low-pressure and temperature applications, such as in smaller motors and engines. It is also useful for biofuels and ethanol fuels and can be used in enclosed spaces. However, PVC piping is stiffer than other options, limiting its flexibility in use. PVC is not suitable for high-pressure applications as it may burst or break, and high temperatures can cause warping, leading to potential safety issues.
Rubber fuel hoses, on the other hand, are suitable for high-pressure applications like fuel injection engines and marine applications. They are also used in automotive fuel delivery systems and logistical fuel transport. Rubber is a naturally occurring material, but many fuel hoses use nitrile rubber, a synthetic rubber made from a combination of acrylonitrile and butadiene, which enhances its qualities. Rubber fuel hoses can degrade faster than plastic alternatives, leading to potentially higher replacement costs. Additionally, fumes can leak through certain rubber hoses, so they should not be used in cabins or enclosed areas with people. Rubber is also more susceptible to abrasions, especially around metals, and can wear through if not secured properly.
In terms of installation, rubber fuel hoses are generally easier to install than metal lines, which are typically considered the best material for fuel lines due to their durability. Rubber hoses are connected using standard barbed fittings and fuel line hose clamps and must be rated for fuel or meet specific SAE grades. While rubber hoses are easy to install, they have some downsides, including degradation upon contact with fuel and leakage of fuel vapors, except for J30R9-rated hoses. Nylon tubing, a type of plastic, may be a more budget-friendly option for fuel line repairs compared to long lengths of plain rubber fuel hose.
Ultimately, the decision between rubber and plastic fuel lines depends on the specific requirements and conditions of your application, including the type of fuel, pressure, temperature, and other external factors.
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Frequently asked questions
Plastic fuel lines are prone to bending, bulging, buckling, flattening, and kinking. They also become brittle over time and are affected by UV rays.
Some alternatives to plastic fuel lines include rubber lines, viton-lined rubber lines, and Bundy-Flex copper lines.
There are a few ways to add a new fitting to a hard nylon fuel line. One way is to use a clamp block similar to a brake flaring tool. Another way is to heat the line with a heat gun or boiling water before attaching the fitting.
When splicing into hard plastic fuel lines, it is important to use hose barb fittings and to heat up the ends of the lines with a heat gun or boiling water before inserting the fittings.
To form a sharp bend in a plastic fuel line without kinking, you can use a shaping mandrel or a bendable forming tool. You can also try heating the line with boiling water to make it more pliable.
