Upgrade Your Steel Fuel Lines To Braided: A Step-By-Step Guide

Replacing steel fuel lines with braided lines is a complex process that requires careful consideration and planning. The first step is to assess the condition of the existing fuel lines and determine if they need to be replaced. If the steel fuel lines are corroded or damaged, it is recommended to replace them with braided lines, which offer improved durability and performance. Braided lines, such as those made of stainless steel or Teflon-coated hoses, are designed to withstand modern gasoline and provide a longer-lasting solution. However, it is important to note that some braided lines may not meet EPA, SAE, and CARB standards for permeation, and they can be more expensive than traditional steel lines. When replacing fuel lines, it is crucial to follow safety guidelines and adhere to fuel system integrity standards set by regulatory bodies.

Consider the cost and your budget

When considering the cost and your budget for replacing steel fuel lines with braided lines, it's important to weigh the different options available and their respective advantages and disadvantages. Here are some key points to consider:

First, replacing the entire line with a pre-bent line can be the most expensive and labor-intensive option. This involves purchasing a new line from aftermarket or new car dealer sources. While this option offers a long-lasting repair and returns your vehicle to like-new condition, it may not be feasible for all vehicles and can put a strain on your wallet.

Second, bending your own lines can be a more cost-effective choice if you're willing to invest in bending and flaring tools. Buying a tool that can make quick disconnect fittings can be pricy upfront but may pay off in the long run by increasing productivity and reducing wait times for parts.

Third, nylon tubing and specific fittings provide a more budget-friendly alternative. This option can be used for the entire length of the fuel line or just a section, making it a versatile and economical repair when pre-bent lines are not available.

Additionally, it's worth noting that standard rubber or a combination of rubber and hard lines can be a more affordable choice for stock vehicles. They can get the job done without breaking the bank.

Lastly, when considering braided lines, keep in mind that traditional braided lines with rubber cores will eventually break down, and not all options on the market are compatible with ethanol-blended fuels. PTFE (Teflon) lined braided hoses, which are designed to handle ethanol, tend to be smaller in outer diameter and have higher-priced fittings.

In conclusion, the cost of replacing steel fuel lines with braided lines can vary depending on the chosen option and the specific vehicle. It's important to research and compare prices for the different options, tools, and fittings required to make an informed decision that aligns with your budget.

Think about the pros and cons of braided lines

Braided fuel lines are a popular choice for car enthusiasts and performance-driven applications. They offer a range of benefits that make them a preferred option in certain situations. However, it's essential to consider both the advantages and disadvantages before making a decision. Here are some key points to think about:

Pros of Braided Fuel Lines:

• High-Pressure Tolerance: Braided fuel lines, such as those made of braided stainless steel, can handle significantly higher pressures compared to nylon lines. This makes them ideal for high-performance vehicles and racing applications.
• Durability: The braided exterior provides excellent protection against physical damage, chemical exposure, and heat. This protective layer extends the lifespan of the fuel line, making it a long-lasting option.
• Appearance: Many car enthusiasts prefer the aesthetic appeal of braided fuel lines, which can enhance the overall look of the engine bay.

Cons of Braided Fuel Lines:

• Cost: Braided fuel lines tend to be more expensive than nylon options. The fittings and tools required for installation can also add to the overall cost.
• Installation Complexity: Braided fuel lines may require specialist tools and skills for proper installation. This complexity can make the process more challenging and time-consuming.
• Inner Condition: The braided exterior can sometimes hide the condition of the inner rubber hose, making it difficult to detect deterioration or cracks.
• Permeability: Some braided fuel lines may not meet EPA, SAE, and CARB standards for permeability, allowing fuel vapour loss.
• Compatibility: Not all braided hoses are compatible with modern fuels, especially those with higher ethanol content. It's important to choose the right type of braided hose to avoid degradation and failure.

When deciding whether to switch to braided fuel lines, it's essential to consider your vehicle's specific needs, driving conditions, and maintenance commitments. Braided fuel lines are ideal for performance vehicles that require high-pressure resistance and longevity. However, for everyday vehicles where flexibility and cost-effectiveness are priorities, other options like nylon fuel lines might be more suitable.

Understand the process of bending your own lines

Bending your own fuel lines can be a tricky process, but with the right tools and techniques, it can be done successfully. Here are some key steps and considerations to help you understand the process of bending your own lines:

• Use a tubing bender: A tubing bender is a crucial tool for bending fuel lines without kinking or damaging them. Choose a bender that has a rigid groove to securely hold the tubing while you pull or bend it. Some benders have a ratcheting pistol grip with a die that comes straight up, forcing the bend against two shoes, making it easier to work in tight spaces.
• Prepare the tubing: Before bending, it's important to clean the tubing and ensure there are no obstructions. Lightly grease the tubing to facilitate the bending process, but avoid greasing the area where the tubing will be clamped into the bender.
• Use a bending spring: Bending springs are essential to prevent kinking during the bending process. Slip a bending spring that fits tightly over the fuel line to provide support while you bend it by hand. You can usually find these springs in the plumbing section of hardware stores.
• Heat the tubing: In some cases, applying heat to the tubing can make it more pliable and easier to bend. Use a heat gun or boil the tubing in water, being careful not to overheat and weaken the material. Allow it to cool completely before handling further.
• Use a supplemental wire: Inserting a wire or coat hanger inside the tubing can help you achieve a more precise bend. Bend the wire to the desired shape, leaving a little extra on each bend, then heat the assembly and dunk it in cold water to set the shape. Remove the wire afterward.
• Fill the tubing: Another technique is to fill the tubing with a non-compressible substance, such as sand, to prevent it from collapsing during bending. Cap the ends, bend to the desired shape, then empty and flush out the tubing afterward.
• Bend gradually: When bending by hand, work in small increments. Bend a little at a time and gradually work your way down the tube until you achieve the desired shape. This helps to prevent kinking and ensures a more controlled bend.
• Use fittings: In some cases, it may be more practical to use fittings or adapters to create sharp bends, especially if you're working with rubber fuel lines. This can help you avoid kinking and maintain a smooth fuel flow.
• Cutting the tubing: Invest in a good tubing cutter to ensure clean, square cuts. A ratcheting tubing cutter or brush cutters can provide more precise and safer cuts compared to using a razor knife.
• Practice and patience: Bending fuel lines may take a few attempts to perfect. Be prepared to experiment with different techniques and heat levels to find what works best for your specific application.

Remember to take appropriate safety precautions when working with fuel lines, and always work in a well-ventilated area when using heat.

Know the different types of fittings and how to connect them

When it comes to fittings, there are several types to be aware of and each has its own specific use. The first type is the AN fitting, which stands for Army-Navy. These fittings are often found in high-performance and race cars and are used for fuel, oil, coolant, and hydraulic fluids. They use a 37-degree flared fitting to create a metal-to-metal seal and are known for providing a secure and reliable connection. AN fittings can also come in non-swivel or swivel variants, making installation easier.

Another type of fitting is the NPT fitting, which stands for National Pipe Thread. These fittings are used on fuel systems and oil coolers to adapt female NPT ports to accept AN fittings or hose ends. They can also be used to connect fuel lines to the port on a fuel pump or pressure regulator. However, sealing tape or compound is required to prevent leakage.

O-Ring Boss fittings, or ORB fittings, are similar to NPT fittings but use a straight thread and a 37-degree cone to create a seal. They are commonly used in performance fuel rails, water or fuel pumps, and fuel tank modules. Like AN fittings, they require O-rings to seal properly.

Adapter fittings, also known as standard or union fittings, are used to connect fuel lines to fuel pumps, regulators, and filters. They can be found in SAE size configurations but are more commonly manufactured to AN standards, featuring a 37-degree cone on each end.

Pipe fittings are used to connect fuel lines to ports on fuel pumps, pressure regulators, and gauges. One end of the fitting is a male open-ended cylinder with tapered threads, while the other end typically uses a 37-degree cone and straight thread. Pipe fittings do not use O-rings and require sealing tape or compound to prevent leakage.

Port fittings, also known as ORB fittings, conform to AN standards and are the preferred choice for high-end racing and performance fuel systems. They use straight threads and a 37-degree cone, requiring O-rings to create a reliable seal.

When replacing steel fuel lines with braided lines, it is important to identify the correct fittings for your specific application. Braided lines, such as those made of stainless steel or nylon, often require AN fittings and the appropriate assembly tools.

Learn about the potential issues with rubber hoses

Rubber fuel hoses are easy to install and are typically connected using standard barbed fittings and fuel line hose clamps. However, they have several downsides and are not recommended for use in an entire fuel system. Here are some potential issues with rubber hoses:

• Durability: Rubber hoses start degrading as soon as they come into contact with fuel. They are also susceptible to cuts, nicks, and other abrasions, which can compromise their integrity over time.
• Fuel Vapour Leakage: With the exception of J30R9-rated hoses, rubber hoses can leak fuel vapours, leading to a strong raw fuel odour in your garage or vehicle.
• Heat Resistance: Rubber hoses have limited heat resistance and can deteriorate when exposed to high temperatures, such as those near the exhaust pipe. This can pose a safety risk.
• Cost: While initially cheaper, the long-term maintenance and replacement costs of rubber hoses can be higher compared to other options.
• Safety: Rubber hoses are more prone to damage from road debris and accidents, which can lead to fuel leaks and safety hazards.

To address these issues, it is recommended to use alternative materials such as nylon tubing, braided stainless steel lines (with Teflon coating), or PTFE-lined hoses for fuel line repairs and replacements. These options offer improved durability, resistance to fuel vapour leakage, and compliance with safety standards.

Frequently asked questions