Rajan Wilcox
Making your own GM fuel lines can be a challenging task. It is important to note that you cannot make the fittings GM uses, and you will need to use a different adapter. There are several tools available for bending and flaring tubes, with prices varying according to quality. It is recommended to use a lubricant at the flaring head and line end to make the process smoother. You can also send your specifications to a company that will bend and form lines according to your blueprint.
Characteristics and Values Table for Making GM Fuel Lines
| Characteristics | Values |
|---|---|
| Materials | Steel, stainless steel, aluminum tubing |
| Tools | Tube bending and flaring tools, hacksaw, tubing cutter, hydraulic flare tool |
| Lubricants | Low-viscosity engine oil, WD-40, brake fluid, power steering fluid |
| Fittings | Saginaw to -AN adapters, AN fittings, quick-connect ends |
| Line Sizes | 3/8", 5/16" |
| Kits | Mastercool GM Fuel Line Flaring Kit |
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What You'll Learn
Using a flaring tool to create a 45-degree flare
Fabricating your own fuel lines can be a rewarding project, allowing you to personalise your vehicle and route the lines where you want them. When creating a 45-degree flare, the process is generally the same across different vehicles and can be done at home with the correct tools.
First, you will need to cut your fluid line to the proper length and bend it to your desired shape. It is important to ensure that the line ends are completely free of burrs and imperfections. Some professionals suggest using a hacksaw instead of a tubing cutter, as the latter can work-harden stainless steel, making it tougher to achieve a proper flare.
Once your line is cut and bent to your desired specifications, you can begin the flaring process. The 45-degree flare is a two-step process that creates a double-walled flare seat. This style of flare does not require a tube sleeve or flare seat support due to the extra wall thickness of the double flare. It is also known as an SAE (Society of Automotive Engineers) or IFF (inverted flare fitting) flare. This type of flare has external or male threads on the fitting.
To create the 45-degree flare, you will need a flaring tool such as the ARES 18010 Universal Hydraulic Flaring Tool Set or the Mastercool GM Fuel Line Flaring Kit. These tools come with a hydraulic cylinder and various dies and adapters to help you create the flare efficiently. 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.
By following these steps and taking your time, you can successfully create a 45-degree flare using a flaring tool for your GM fuel lines.
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Bending and flaring your own lines at home
First, you'll need to gather the right tools and materials. Tube bending and flaring tools are readily available from suppliers like Harbor Freight Tools and The Eastwood Company, offering options to suit different budgets. Stainless steel tubing is a popular choice for its durability and corrosion resistance, but it is more challenging to work with than galvanised steel due to its higher hardness. If you're a beginner, consider starting with galvanised steel or Poly-Armour® soft steel, which bends and flares more easily. Don't forget to also get a good lubricant—for fuel lines, a low-viscosity engine oil or WD-40 is recommended.
Once you have your tools and materials, it's time to plan your bends. Mapping out your bends beforehand will help you avoid frustration during the flaring process. Keep in mind that tight bends and short leads to the flare can be tricky, so take your time and practice on some scrap tubing if possible. When you're ready to start bending, use a hacksaw to cut your tubing to the desired length, ensuring the ends are free of burrs and imperfections.
Now, you can begin the bending process. If you're using pre-flared lines like Poly-Armour® sticks, you can simply bend them by hand or with basic bending tools. For more complex bends, lever-action benders offer greater control and accuracy. As you work, remember to take your time and get each bend right—rushed jobs can lead to leaks and time-consuming repairs.
Finally, it's time for flaring. Apply lubricant to the flaring head and line end to ensure a smooth process. Then, use your flaring tool to create a double 45-degree flare on each line end and fitting. This step can be challenging, especially with stainless steel, so invest in a good-quality flaring tool to achieve the best results.
By following these steps and taking your time, you can successfully bend and flare your own fuel lines at home, adding a unique personal touch to your vehicle.
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Using a hacksaw for stainless steel
When making GM fuel lines, you may need to cut through stainless steel. While a tubing cutter may be used, some seasoned tube bending professionals suggest using a hacksaw instead. This is because a tubing cutter will work-harden stainless steel, making it tougher to get a proper flare. It is also virtually impossible to get a good double flare from stainless steel.
If you are cutting stainless steel with a hacksaw, you should use a greased fine-tooth blade. This will ensure a clean cut. You should also ensure that the line ends are completely free of burrs and imperfections. This is important because stainless steel is a harder material than conventional galvanized steel.
When cutting fuel lines, it is important to avoid creating any sparks and starting a fire. Therefore, you should not use electric tools. A junior hacksaw blade wrapped in a cloth can be used, but it may be challenging to get full strokes and you can only use the tip of the blade. An air hacksaw can be used as an alternative, but you should ensure that it does not create any sparks.
If you are cutting the fuel lines in place, you should do it outside with plenty of ventilation. You should also use compression fittings, not rubber hoses, when putting the fuel lines back.
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Using lubricants to make the process smoother
When fabricating your own GM fuel lines, using lubricants can make the process smoother and easier. While it is possible to purchase pre-bent lines for a quick bolt-on solution, fabricating your own lines gives you the ultimate personalisation for your vehicle.
There are a variety of tube bending and flaring tools available to help you bend and flare your own fuel lines. When you are flaring brake and fuel lines, it is recommended to use a lubricant at the flaring head and line end. This makes the process smoother and helps to avoid cockeyed and incomplete flares, which can cause time-consuming leaks.
For GM fuel lines, it is recommended to use a low-viscosity engine oil or even WD-40 as a suitable lubricant. This is because the lubricant should be compatible with the medium your lines will carry. Using the correct lubricant is important as fuel-lubricant interactions can impact the viscosity of the lubricant, sump oil levels, friction and wear, and can even cause low-speed pre-ignition.
When choosing a lubricant for your GM fuel lines, it is important to consider the type of fuel your vehicle uses. For example, diesel fuel that builds up in the lubricant sump can be more persistent and may not evaporate easily. On the other hand, gasoline vehicles tend to have higher levels of fuel dilution for short-trip, cold-start driving, but the gasoline built up in the sump will evaporate once the engine is fully warmed up.
By using the appropriate lubricant and taking the necessary precautions, you can ensure that the process of fabricating your own GM fuel lines is smoother and more successful.
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Buying a flaring kit
When buying a flaring kit for GM fuel lines, there are a few things to consider. Firstly, it is important to choose a kit that is compatible with GM fuel lines. Some kits are designed specifically for GM fuel lines, such as the Mastercool 72400 GM Fuel Line Flaring Kit, which can be found on Amazon and other specialty stores. This kit includes a Hydra-Flare Yoke and Pump assembly, as well as GM adapters and die sets in both 5/16" and 3/8" sizes. It is designed to fabricate the special flares found on most GM fuel lines and some GM truck power steering pump return lines. The handheld hydraulic press makes the process quick and easy, and the kit comes in a custom-molded carrying case for convenient storage.
Another factor to consider when buying a flaring kit is the type of tubing you will be working with. For example, stainless steel is harder than galvanized steel and requires different techniques and tools. If you plan to work with stainless steel, it is recommended to invest in higher-quality tools, such as a multi-headed flaring tool, as it can be more challenging to achieve a good flare with lower-quality tools.
The price of the flaring kit is also an important consideration. Flaring tools can range from $12 to $22 for double-flaring tools, with more expensive options available for multi-headed tools. It is generally recommended to opt for higher-quality tools when possible, as they tend to provide better results and last longer. However, it is important to consider your budget and how often you plan to use the tools, as you may not need the most expensive option if you are only doing occasional projects.
Finally, it is worth considering the additional features and accessories that come with the flaring kit. For example, some kits come with a custom-molded carrying case, which can be useful for storing and transporting the tools. Additionally, some suppliers may offer loyalty rewards programs or newsletters with promotions and discounts, which can be beneficial if you plan to make multiple purchases.
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Frequently asked questions
You can purchase a GM Fuel Line Flaring Kit from various retailers. The kit comes with a handheld hydraulic press, a Hydra-Flare Yoke & Pump Assembly, GM Fuel Line Adapters, and Die Sets. You can also purchase tube bending and flaring tools from Harbor Freight Tools and The Eastwood Company.
It is suggested that you 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.
The size of the fittings depends on the stock size of your fuel lines. The stock size could be 3/8 & 5/16.
Some professionals suggest using a hacksaw instead of a tubing cutter because a tubing cutter will work-harden stainless steel, making it tougher to get a proper flare.
