Regan Brown
Bending a fuel line can be a tricky task, especially if you want to avoid kinks and are working with rubber or stainless steel. The process can be made easier with the use of a bender, which can be purchased or borrowed, and the application of heat. It is also important to consider the type of fuel line you are working with, as different materials have different physical characteristics and may require different methods to bend effectively. For example, a spring inside a rubber hose can prevent kinking, while stainless steel is harder to work with than galvanized steel.
How to Mend a Fuel Line
| Characteristics | Values |
|---|---|
| Tools | Bender, hacksaw, tubing cutter, tube bending and flaring tools, heat gun, stove, jig, wire, sand |
| Materials | Steel, stainless steel, aluminum, copper, vinyl, poly, rubber |
| Techniques | Bending by hand, using a spring, heating and cooling, filling with sand, using a lubricant |
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What You'll Learn
Bending a rubber fuel line
First, decide on the desired shape of the bend. If you are aiming for a 90-degree bend, consider adding hose ends or fittings to make it easier. If you need to make a complex bend, you can use a stiff wire to create a former. Bend the wire into the desired shape, then slide the fuel hose over it.
Next, you will need to heat the hose to mould it into the desired shape. Dunk the hose-covered wire in a bowl of very hot or boiling water for several minutes. Then, rinse it in cold water and remove the wire. Your rubber fuel line should now retain the shape of the wire.
Alternatively, you can use a heat gun or torch to heat the hose. However, be cautious as too much heat can damage the hose. It is important to note that some sources suggest that it is not possible to reshape a fuel hose after it has been manufactured due to the special moulding process used.
If you do not want to attempt a custom bend, you can use a bending spring. Slide the spring over the fuel line and bend it to the desired shape with your hand. The spring will help you make sharper bends without kinking the hose.
Finally, to prevent kinking, you can lightly grease the tubing before bending it. However, do not grease the area where the tubing is clamped into the bender. Additionally, ensure that the tubing is held captive in the bender, and the bender has a rigid groove to hold the tubing while the end is pulled or bent.
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Using a tube bender
There are several types of tools available for the job, from simple radius tools to more accurate lever-action benders. The key to using a bending tool is to get a quality tool that won't kink the line. While Poly-Armour® lines resist kinking, unlike plain steel, it is still possible to kink the line. Simple benders are single-piece tools that use a hook-type latch to lock the tubing in place. They are fairly cheap but have a high chance of ruining a piece of tubing as they don't secure the line, so complicated bends can easily become out of line.
Spring-type benders are another option and are meant mainly for copper and aluminum tubing. There are two types: internal and external. Both prevent the tube from collapsing and kinking while hand bending and are best for gentle, large-diameter bends. The top tool is the best lever-action bender as you have more control over the bend. If you are replacing a line, use the existing line as a reference. Start at one end and recreate the line bend for bend. You can even add some tape as you go to keep the bends in line.
When bending the line, don't forget the flares and fittings. Slide the fitting all the way to the flare before bending the line, otherwise, you will have to straighten the line or cut and reflare it. It's also a good idea to use a piece of tape to hold the fitting at the end of the line by the flare. When making bends near the end of the line, make sure to add a flare before bending the line, as your flare tool needs room ahead of the bend.
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Flaring tools
Speedway Motors Deluxe 37 Degree AN Line Flaring Tool
This flaring tool is made of hardened steel and can create smooth flares. It has a slip-on yoke and is self-gauging. It is perfect for creating flares in brake and fuel lines.
InnoHHustle 6 Pcs Double Flare Adapter 3/16"+1/4" Brake Flaring Tool Kit
This stainless steel double flare tool kit includes six pieces and can be used for brake and fuel lines. It is available on Walmart for $11.68.
Eastwood Professional Brake Line and Tubing Flaring Tool
The Eastwood Pro Brake Flaring Tool allows users to create three kinds of precision flares in five sizes of tubing. It can be used on brake lines, transmission cooler lines, and fuel lines. The kit includes five different-sized dies, a lever handle, instructions, and a carrying case.
Ratcheting Flare Nut Brake Line Wrench
This flare nut wrench can be used as a hand tool for brake, fuel, transmission lines, and cables. It comes in different variants, including metric and open flex.
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Fabricating your own fuel lines
First, decide on the type of tubing you want to use. You can choose from steel, stainless steel, or aluminium tubing, each with its own advantages and challenges. Stainless steel, for example, is stronger but more difficult to work with than galvanised steel. Aluminium is another option for fuel lines. You can purchase these materials from suppliers like Classic Tube, who offer rolls of tubing that you can custom bend and flare to your desired shape.
Next, gather the necessary tools for bending and flaring the tubing. Tube bending and flaring tools are readily available from suppliers like Harbor Freight Tools and The Eastwood Company, catering to various budgets. A good bender, such as one with a ratcheting pistol grip, can make the job much easier, especially when working in tight spaces. Additionally, consider using bending springs to support the tubing while you bend it by hand, preventing kinks and ensuring smooth curves.
When it comes to the flaring process, it's important to use a lubricant compatible with the medium your lines will carry. For fuel lines, a low-viscosity engine oil or WD-40 can be used as a lubricant at the flaring head and line end. This will ensure a smoother flare and help prevent issues like leakage. Take your time during the flaring process, as cockeyed and incomplete flares can cause problems down the line.
Finally, if you're working with pre-existing fuel lines, you can use them as a template to create new ones. Alternatively, you can send your specifications to companies like Classic Tube, and they will fabricate new lines according to your blueprint.
By following these steps and paying attention to detail, you can successfully fabricate your own fuel lines, adding a unique touch to your vehicle.
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Avoiding kinking
When mending a fuel line, it is important to avoid kinking, which can cause issues such as fuel starvation. Here are some ways to avoid kinking when working with fuel lines:
Firstly, consider the type of material used for the fuel line. Metal lines made of stainless steel, aluminium, or copper are less likely to kink than rubber lines. Copper or nickel tubing, in particular, is easier to bend without kinking but should be kept away from heat sources to prevent fuel boiling or vapour lock issues. If using a rubber fuel line, consider inserting a spring inside the hose before bending it to the desired shape. This will prevent kinking, but you must find a spring of the correct size.
Another method to avoid kinking is to fill the fuel line with table salt or sand before bending. The filler material provides support during the bending process. After bending, simply flush out the salt or sand with water. It is important to note that sand can turn to mud when wet, which can stick to the inside of the tubing, so salt is a better option.
For more complex bends, you can use a tubing bender. These tools can be purchased from auto parts stores or online. It is recommended to invest in a good quality tubing bender to achieve the desired results without damaging the fuel line. Additionally, a double flare tool is useful for creating custom bends and ensuring leak-proof connections.
Finally, some people suggest using a heat gun to shape the fuel line. However, this method may not work for all types of fuel hoses, and it is important to apply the correct amount of heat to avoid weakening the hose. It is recommended to research the specific type of fuel line you are working with to determine if heat-forming is suitable.
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Frequently asked questions
You can bend a fuel line by hand, but this can be challenging and may result in kinks. Using a tube bender can make the process easier. If you are bending a rubber fuel line, you can fill it with sand, bend it, and then empty and flush it out. You can also try inserting a stiff wire into the line, bending it to shape, and then placing it in warm water for five minutes before placing it in cold water to set the shape.
Stainless steel is a good option for fuel lines because it is durable and virtually never corrodes. However, it is a challenging material to work with because it is much harder than conventional galvanized steel.
To prevent kinks in a fuel line, you can use a spring inside the tubing to keep it in the correct shape. This is called an anti-kink spring.
You must have a double 45-degree flare for fuel lines. It is also suggested that you use a lubricant at the flaring head and line end to make the process smoother. For fuel lines, you can use a low-viscosity engine oil or WD-40 as a lubricant.
Yes, you can fabricate your own fuel lines at home. Tube bending and flaring tools are available from a variety of sources and are designed to fit many budgets. You can also send your specifications to a company like Classic Tube, and they will bend and form lines to your blueprint.
