Sylvie Willis
Making your own steel fuel lines and fuel fittings can be a challenging but rewarding task. It requires careful planning and execution, as well as the use of appropriate tools and materials. In this guide, we will cover the essential steps, including choosing the right type of steel, bending and flaring techniques, and ensuring safe and reliable connections. We will also explore the benefits of using steel over other materials, such as its durability and corrosion resistance. By the end of this guide, you should have the knowledge and skills necessary to fabricate custom steel fuel lines and fittings that meet your specific requirements.
How to make steel fuel lines and fuel fittings
| Characteristics | Values |
|---|---|
| Materials | Steel, stainless steel, or aluminum tubing |
| Tools | Tube bending and flaring tools, hacksaw, tubing cutter, MASTERCOOL flaring tool, vise with soft jaws, diagonal cutters, flat-head screwdriver, wrench |
| Lubricants | Brake fluid, low-viscosity engine oil, WD-40, power steering fluid, automatic transmission fluid, 3-in-1 oil, antiseize |
| Fittings | AN fittings, brass fittings, bundyweld tubing |
| Process | Cut, crimp, flare, and bend tubing to desired shape and size; remove and reuse fittings; slip on ferrules; measure and mark; tighten and secure fittings |
| Tips | Use lubricant when flaring, remove gas/fuel residue, ensure line is "all the way home" or bottomed out, check for kinks/tight bends, test connection before use |
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What You'll Learn
Cutting and preparing the steel fuel line
When it comes to cutting and preparing a steel fuel line, there are several steps to follow. Firstly, disconnect the fuel line and remove all existing fittings attached to it. It is recommended to reuse as many of the fittings as possible, except for the ferrules and the fuel line itself. Removing the fittings can be challenging, so heating the line to soften it can help. Ensure the line is free of any fuel or gas residue.
Once the fittings are removed, take the original bare fuel line and measure its total length. This measurement will guide the length of your new fuel line. Cut your new steel fuel line to the desired length, ensuring it matches the measurement of the old line. After cutting, slip a ferrule onto each end of the new line. It is crucial to ensure that the fuel line is bottomed out on the fittings before crimping to prevent errors in length.
When cutting the steel fuel line, it is important to use the appropriate tools. While tube bending and flaring tools are available at various price points, a hacksaw is recommended for cutting stainless steel. This is because a tubing cutter can work-harden stainless steel, making it more difficult to achieve a proper flare. Taking the time to ensure precise cuts and flares is essential to avoid future leaks.
Additionally, when fabricating steel fuel lines, it is mandatory to apply a double flare to every line end and fitting. This is especially critical for brake lines, which must withstand extreme pressures in a hydraulic braking system. For fuel lines, a single flare or compression is usually sufficient. Using a lubricant at the flaring head and line end can facilitate a smoother process. For fuel lines, a low-viscosity engine oil or WD-40 is recommended as a lubricant.
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Bending and flaring tools
The Eastwood kit is highly regarded as it takes the guesswork out of it. It is a one-hand operation and is the tool with the least amount of loose small parts. The Mastercool tool, on the other hand, requires two hands and has more physical motions to form a double flare. It also has more loose parts and some users have reported leakage issues.
Another option is the Imperial Bender, which can be used for both bench and on-the-car applications. The multi-headed flaring tool is an expensive option but a good investment if you do a lot of line fabrication, especially in stainless steel.
When fabricating lines, it is vital to take your time and get it right. Cockeyed and incomplete flares can lead to time-consuming and costly leakage issues. For stainless steel, it is recommended to use a hacksaw instead of a tubing cutter to ensure the line ends are completely free of burrs and imperfections.
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Removing and reusing fittings
If you are looking to remove and reuse fittings, it is important to first assess the type of fuel line and fitting you are working with. For example, if you are dealing with a broken fuel line, you will need to use a tubing cutter to remove it. Make sure to cut as far back as necessary, leaving at least 3 inches of a straight line to install the compression fitting.
If you are working with a quick connector, you may need special tools to remove it. Spring locks and nylon safety clips are commonly used and require specific tools to release the fitting. It is also important to be cautious when working with nylon lines, as they tend to break near the fuel filter due to the force and twisting required for removal.
When reusing fittings, it is important to ensure you have the correct size line or fitting needed for the replacement. Mark where to cut the line, and use a nylon line cutter to make the cut. Place the opposing ends of the fuel lines into the block's threaded side, allowing for a small protrusion. Use oil on the tapered connector to help with the connection.
Additionally, when reusing fittings, you may need to heat the fitting or the line to ensure a proper connection. This can be done with boiling water or a heat gun, but be cautious when working with fuel lines and heat sources. It is important to follow safety protocols and work in a well-ventilated area when dealing with fuel lines.
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Lubricating the fittings
However, if you are still interested in lubricating the fittings, there are a few options available. One option is to use a product specifically designed for this purpose, such as United-Erie "EZ Turn Fuel Lube" (SAE or Mil Spec "G-6032D"). This product forms a non-hardening layer between the metal and rubber parts, making it easier to remove the hoses without ripping or distorting them. Another option is to use a hose lubricant like Earls hose lubricant, which is designed for assembling AN fittings onto braided hose.
It is worth noting that some people have expressed concerns about the longevity of these lubricants, wondering if they will still be effective after a few years. Additionally, any lubricant used on rubber hoses should be fuel-resistant to prevent leaking fuel, which could be dangerous.
For metal fittings, options such as Vaseline, fuel or motor oil, silicone, and dish soap have been suggested. These lubricants can help make the fittings easier to work with and may be more readily available or affordable than specialty products. However, it is important to note that some of these options, such as Vaseline, may not be recommended for use on rubber surfaces.
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Final installation
Before beginning the final installation, ensure that you have selected the appropriate thread sealant compatible with the type of fuel (diesel or gasoline) or oil that will be running through the line. Liquid or paste-type thread sealants are recommended to avoid clogging issues.
Now, let's get started with the final installation:
- Assembly and Testing: First, assemble your steel fuel lines and fittings according to the instructions provided by the manufacturer or a trusted source. Take your time and ensure that all connections are secure and properly sealed. Once the assembly is complete, it is highly recommended to have the system pressure-tested by a professional to ensure there are no leaks or hazards.
- Installation: After confirming the integrity of your assembly, proceed with the installation. If you are working with a vehicle, ensure that the vehicle is securely supported, and refer to a guide specific to your vehicle's make and model if possible. Position the fuel lines and fittings according to the layout designed, ensuring that the lines are not kinked or bent excessively.
- Securing Connections: Secure all connections using appropriate clamps, such as marine-grade stainless steel clamps for hose barb connections. Ensure that the clamps provide even sealing tension to prevent leaks. Double-check that all fittings are installed correctly and consider using a lubricant compatible with the medium your lines will carry to make the process smoother.
- Final Checks: Once everything is in place, tighten all connections and perform a final inspection. Verify that the fuel lines are securely attached and that there are no signs of leaks or damage.
- Professional Inspection: While this step is optional, it is highly recommended, especially for installations involving fuel systems. Have a certified marine professional or mechanic inspect your work to ensure that it complies with safety standards and that there are no potential hazards.
By following these steps for the final installation, you can ensure that your steel fuel lines and fittings are properly installed, safe, and functional. Remember, working with fuel systems can be dangerous, so always prioritize your safety and consult professionals if you have any doubts or concerns.
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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. Bending and flaring tools are designed to fit many budgets.
First, disconnect the fuel line and remove all existing fittings attached to the line. Then, heat the line to allow it to soften and proceed to remove the fittings. Measure the length of the original fuel line and cut your new steel fuel line to the exact size. Slip a ferrule on each end of the line and, before crimping, ensure your fuel line is pushed "all the way home" or bottomed out on the fittings. Finally, install the new fuel line assembly, ensuring there are no kinks or tight bends.
It is mandatory to apply a double flare to every line end and fitting. When flaring, 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. Additionally, ensure that line ends are completely free of burrs and imperfections.
