Mercedes Mullins
Making your own hard fuel lines is a great way to personalize your vehicle. It can be done at home with the right tools and materials. Tube bending and flaring tools are available at various price points and can be used to create custom fuel lines. Stainless steel is a popular choice for its durability, but it is more challenging to work with than galvanized steel. Aluminum is another option, but it may not be suitable for high-pressure applications. When creating hard fuel lines, it is important to take your time to ensure proper flaring and avoid leaks.
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What You'll Learn
Tube bending and flaring tools
When selecting a tube-bending tool, it is important to consider the type of material being used. For example, stainless steel is harder to work with than galvanized steel and may require a hacksaw or tubing cutter. Some professionals suggest using a hacksaw instead of a tubing cutter to avoid work-hardening the stainless steel and making it tougher to flare.
There are also different types of flares that can be created with the right tools. Brake lines, for instance, require a double 45-degree flare to withstand the extreme pressures in a hydraulic braking system. AN fittings, on the other hand, typically use a 37-degree flare. It is important to use the proper die to create the initial bubble flare before rolling the sides into the desired flare shape.
Additionally, 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. For brake lines, brake fluid can be used as a lubricant. It is also important to ensure that the line ends are clean-cut and free of burrs and other irregularities before flaring.
Overall, tube bending and flaring can be done at home with the right tools and careful execution. Taking the time to do it right will ensure that your project is safe and successful.
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Stainless steel vs galvanized steel
Making your own fuel lines can be a challenging but rewarding task. There are a few options for the type of tubing you can use, each with its own pros and cons. This article will focus on two of the most common materials: stainless steel and galvanised steel.
Stainless steel is a popular choice for fuel lines due to its durability and resistance to corrosion. It is harder than galvanised steel, making it more challenging to work with, especially when bending and flaring. It is also more expensive. However, with the right tools and some practice, it is not much harder to work with than plain steel. It is worth investing in a good-quality tubing bender and flaring tool, as well as some scrap tubing to practice on.
Galvanised steel, on the other hand, is a more cost-effective option and is generally easier to work with. It can be purchased from local automotive stores and is available in various sizes. However, it may not be as durable or corrosion-resistant as stainless steel. Some sources suggest that the inside of the tubing should not be coated, as this could potentially cause issues.
Both materials require a double flare of 45 degrees at each end of the tubing to contain the extreme pressures of the braking system. When flaring, it is recommended to use a lubricant at the flaring head and line end to ensure a smooth process.
Other materials that can be used for fuel lines include aluminium and epoxy-coated steel. Aluminium is easy to work with and can be purchased from most automotive stores. However, it may crack when flared and can corrode internally if fuel is left in it for extended periods. Epoxy-coated steel is also an option, although some sources suggest avoiding coatings on the inside of the tubing.
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AN or Army-Navy fittings
When making hard fuel lines, it is important to consider the type of fittings you will use to connect the various parts of the fuel system. AN or Army-Navy fittings are a standardised type of fitting often used in high-performance applications. They are known for their reliability and come in various sizes.
AN fittings were originally designed for use in aerospace and military applications. Today, they are commonly used to plumb fluids in high-performance vehicles. Any fluid in a car can be plumbed using an AN hose, and they are especially useful for heavy-duty and high-performance applications. The choice of fuel line size depends on the fuel flow requirements of your engine, the pressure levels in your fuel system, and the compatibility with your chosen fittings.
AN fittings use a 37-degree flare instead of a standard 45-degree flare. This is an important distinction to make when purchasing flare tools and tubing. It is also worth noting that AN fittings have a different flare than brake lines, and while you can use a brake flare tool, you must tighten the fitting down well before flaring. You can purchase AN flare tools from aircraft supply stores, and they are often cheaper than buying them from other places.
When using alum lines, an old trick to bend the lines without kinking them is to use a length of tubing longer than you need, fill it with dry, fine sand, and then bend it with a plumber's bender. This technique may also work for thin-wall steel or stainless steel. It is important to note that you should always use a lubricant at the flaring head and line end when flaring brake and fuel lines to ensure a smooth process and prevent leakage.
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Routing
First and foremost, it is recommended to keep the fuel lines in their original equipment (OE) location. This helps ensure the fuel system's functionality and avoids potential issues caused by altering the original design.
It is crucial to avoid running fuel lines near suspension pinch points, lift points, or inside the vehicle cabin. These areas can pose safety hazards and increase the risk of damage to the fuel lines.
Use insulated clamps to secure the fuel lines firmly every few feet. This helps prevent abrasion and droop, ensuring the lines remain securely in place. Make sure the clamps are tight enough to avoid any unnecessary movement.
Keep the fuel lines away from moving parts such as driveshafts, CV axles, wheels, and steering components. This minimizes the risk of damage and ensures the lines do not interfere with the vehicle's mechanical functions.
Heat is a significant concern when routing fuel lines. Keep the lines away from heat sources, such as the engine or headers, to prevent vapor lock or fire hazards. If it is unavoidable to route the lines near a heat source, be sure to add a heat shield or sleeve to protect the lines. Maintain a minimum distance of 6 inches between the lines and the heat source.
When passing the fuel lines through a panel, use bulkhead fittings or grommets. This provides protection and ensures a secure passage for the lines, reducing the risk of damage or leakage.
Return lines should follow the same path as the pressure line back to the fuel tank. This helps streamline the fuel flow and ensures a more efficient system.
If you're working with odd angles or tight spaces, consider using a hacksaw instead of a tubing cutter. Tubing cutters can work-harden stainless steel, making it more challenging to achieve a proper flare. Additionally, consider using a lubricant at the flaring head and line end to facilitate a smoother process.
Finally, take your time and be meticulous throughout the fabrication process. Cockeyed and incomplete flares can lead to time-consuming corrections and potential leakage issues.
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Using a hacksaw
If you're making your own hard fuel lines, you'll need to be able to cut through metal tubing. One way to do this is with a hacksaw. Hacksaws are a good option if you're working with stainless steel, as tube cutters can work-harden the material, making it tougher to get a proper flare.
However, it's important to note that using a hacksaw can be more challenging and time-consuming than other methods. It can also be difficult to get a clean cut with a hacksaw, and you may need to file down the edges of your cuts to ensure they're smooth. Additionally, there is a risk of creating sparks when using a hacksaw, which could be dangerous if you're working with flammable materials. To minimise this risk, it's recommended to tape up the area you're cutting and have someone standing by with a fire extinguisher.
When using a hacksaw to cut fuel lines, it's important to take your time and measure twice, allowing for enough length to include bends. It's also crucial to ensure that the line ends are completely free of burrs and imperfections, as these can cause leaks or damage other components. One way to do this is by de-burring the cut ends of the tubing.
Overall, while using a hacksaw to make hard fuel lines is possible, it may require more time and effort than other methods. It's important to prioritise safety and take the necessary precautions when working with metal tubing and power tools.
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Frequently asked questions
Tube bending and flaring tools are available from a variety of sources, including Harbor Freight Tools and The Eastwood Company. You can also use a hacksaw, a tubing cutter, a plumber's bender, and a flaring tool.
You can use stainless steel, steel, or aluminum tubing. Stainless steel is harder to work with but it virtually never corrodes and will outlast any other material. Aluminum tubing is not recommended for use in brake systems or applications over 100 psi.
You can use a double flare union to connect two hard fuel lines. You can also use a swedging tool to put one inside the other and sweat it like a copper water pipe.
