Rajan Wilcox
Making your own metal fuel lines is a great way to personalize your car and ensure you get the exact specifications you want. It can be a complex process, and it's important to take your time to get it right. There are a variety of tools available to help you with tube bending and flaring, which you can do yourself at home. You can also send your specifications to a company that will bend and form the lines for you. When flaring your own lines, it is suggested that you use a lubricant at the flaring head and line end to make the process smoother.
Characteristics and Values Table for Making Metal Fuel Lines
| Characteristics | Values |
|---|---|
| Materials | Steel, stainless steel, or aluminum tubing |
| Tools | Tube bending and flaring tools, hacksaw or tubing cutter, MASTERCOOL flaring tool |
| Techniques | Bending and flaring, using lubricants (e.g. brake fluid, low-viscosity engine oil, WD-40) |
| Tips | Use stainless steel for durability, ensure line ends are free of burrs and imperfections, consider pre-bent lines for convenience |
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What You'll Learn
Tube bending and flaring
Classic Tube offers rolls of steel, stainless steel, and aluminium tubing that you can custom bend and flare to your liking. This is especially useful if you are restoring an obscure muscle car for which Classic Tube may not stock pre-bent lines. You can also ship your existing brake and fuel lines to Classic Tube, where they will be used as a template to make new lines. If you don't have the old lines, you can send Classic Tube your specifications, and they will bend and form lines to your blueprint.
When you are flaring brake and fuel lines, it is suggested you use a lubricant at the flaring head and line end. This makes the process smoother when you are flaring the tip. For brake lines, use brake fluid as a lubricant. For fuel lines, use a low-viscosity engine oil or even WD-40 as a flaring lubricant. Power steering lines get power steering or automatic transmission fluid as a lubricant. In short, use a lubricant compatible with the medium your lines will carry. Double-flaring tools are available for $12 to $22 from Harbor Freight Tools. Opt for the higher-priced tools when you can because you generally get what you pay for.
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Using lubricants
When it comes to making metal fuel lines, using lubricants is an important step to ensure smooth flaring and assembly. Here are some detailed instructions and tips on using lubricants for this process:
Selecting the Right Lubricant:
For fuel lines made of metal, it is recommended to use a low-viscosity engine oil or even WD-40 as a suitable lubricant. These options provide the necessary lubrication for the flaring process without causing damage to the metal. It is important to avoid using incompatible lubricants, as they may react negatively with the fuel or the metal itself.
Application During Flaring:
Before flaring the ends of your metal fuel lines, apply the chosen lubricant (low-viscosity engine oil or WD-40) generously to the flaring head and the line end. This will ensure that the metal is adequately coated, promoting a smoother flaring process. Take extra care to avoid getting the lubricant on other parts of the line, as it may not be compatible with all materials.
Compatibility with Other Components:
When assembling the fuel lines, it is crucial to consider the compatibility of the lubricant with other components in the system. For example, if you are using rubber hoses in conjunction with metal fuel lines, opt for a lubricant that is safe for both materials, such as United-Erie "EZ Turn Fuel Lube" or a dedicated hose lubricant like Earl's hose lubricant. These products create a non-hardening layer, facilitating easier disassembly in the future without damaging the hoses.
Working with Stainless Steel:
If you are working with stainless steel to create your metal fuel lines, it is important to note that it is harder than conventional galvanized steel. This makes it more challenging to flare and bend. Consider using a hacksaw instead of a tubing cutter, as the latter can work-harden the stainless steel, making it even tougher to work with. Take your time and be prepared to end up with some scrap stainless steel as you master the technique.
Alternative Lubricant Options:
In some cases, alternative lubricants can be used for metal fuel lines, depending on the specific application and compatibility. Some people have suggested using Vaseline, fuel or motor oil, silicone, or even dish soap. However, it is important to exercise caution when using these alternatives, especially with rubber components, as they may not provide the same level of protection or compatibility as the recommended lubricants.
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Stainless steel vs galvanized steel
Making your own fuel lines is a great way to personalize your ride. You can choose to make them from a variety of materials, including steel, stainless steel, and aluminum tubing. When it comes to stainless steel vs galvanized steel, here are some things to consider:
Stainless Steel:
- Stainless steel is a harder material than galvanized steel, making it more challenging to work with. It requires extra care during the bending and flaring process.
- It is difficult to bend and flare stainless steel, and it work-hardens when bent, making it tougher to get a proper flare.
- A hacksaw is recommended over a tubing cutter to avoid work-hardening the stainless steel, which can make it even harder to flare.
- It is virtually impossible to get a good double flare from stainless steel, and it requires a 37-degree flare.
- Stainless steel is more expensive than galvanized steel.
- On the positive side, stainless steel is highly durable and virtually never corrodes, so it will outlast any other material.
Galvanized Steel:
- Galvanized steel is a conventional choice for fuel lines and is easier to work with than stainless steel.
- It is cheaper than stainless steel.
- It can be coated with epoxy, but some suggest that the inside of the tubing should not be coated.
- Galvanized steel is safe to use with gas and can be used for fuel lines without issues.
In summary, while stainless steel is more durable and corrosion-resistant, it is also more expensive and difficult to work with. Galvanized steel is a more conventional and economical choice but may not last as long as stainless steel. The choice between the two depends on your specific needs, budget, and level of experience in working with these materials.
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Using a hacksaw
When using a hacksaw, it is important to take precautions to minimize the risk of sparks, which could be dangerous when working with fuel lines. One way to do this is by taping up the area that you are going to saw. It is also recommended to have someone standing by with a fire extinguisher as a safety precaution.
Additionally, it is worth noting that a hacksaw may leave a burr that will need to be filed. If this is not done, any rubber fuel line added may be at risk of being cut by the sharp edge. Therefore, it is important to take the time to ensure the line ends are completely free of burrs and imperfections.
When fabricating fuel lines, it is crucial to use the right tools and take your time to get it right. Cockeyed and incomplete flares can lead to time-consuming issues and leakage.
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Splicing metal fuel lines
Splicing a metal fuel line can be a challenging task and it is recommended to avoid splicing if possible. However, if you find yourself in a situation where splicing is necessary, there are a few methods you can use.
One common method is to use compression fittings, which are inexpensive and easy to work with. You can use a basic flarenut tool to create a double flare in the tubing and then join the sections with a compression fitting. This method is suitable for low PSI, mechanical pump fuel lines.
Another option is to flare the ends of the metal line and then push a rubber hose over the flared section, securing it with a clamp. This method also requires the use of a flaring tool, but it is important to ensure that the rubber hose is fuel injection-rated to withstand the pressure.
If you are dealing with a braided stainless steel line, you can cut and rejoin the sections using a metal epoxy. Clean the ends of the line and apply the epoxy before reinstalling it in the same way it was originally attached.
For a more permanent solution, you may need to replace the entire fuel line assembly or create a new solid line from components. This can be done by ordering a replacement from the manufacturer or purchasing the necessary parts and assembling them yourself.
It is important to note that splicing fuel lines should be done with caution and it is recommended to consult a professional or a mechanic if you are unsure about the process.
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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. Double-flaring tools are available for $12 to $22 from Harbor Freight Tools. You will also need a tube cutter.
Classic Tube offers rolls of steel, stainless steel, and aluminum tubing you can custom bend and flare to your liking. Stainless steel is harder than galvanized steel and is therefore more challenging to work with. However, it virtually never corrodes and will outlast any other material.
It is suggested to use a lubricant at the flaring head and line end to make the process smoother. For fuel lines, use a low-viscosity engine oil or WD-40 as a lubricant.
