Katerina Swanson
Running fuel lines is a complex process that requires careful consideration of safety regulations and material suitability. While some prefer to run fuel lines inside the car, others opt for underneath, with both options presenting unique challenges and risks. The type of material used, such as steel, aluminium, or rubber, is also a critical factor that influences the ease of installation and the potential for fuel spoilage or leaks. Understanding the rules and regulations for fuel line installation is essential, especially when it comes to the placement of fuel cells and the use of firewalls. Making your own fuel lines is possible, but it requires the right tools and knowledge to ensure safety and effectiveness.
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What You'll Learn
Running fuel lines inside the car
Running fuel lines inside a car is a controversial topic, with some people arguing that it is unnecessary and unsafe. However, there are certain situations where it may be necessary, such as in rally cars where external fuel lines could be ripped off on rough roads.
If you decide to run fuel lines inside your car, it is important to use the correct materials and follow safety precautions. Avoid using rubber hoses or pipes, as these can be dangerous. Instead, opt for a steel or metal fuel pipe that is properly secured with cushion clamps and has no joins inside the passenger area. Some people also recommend using a braided line inside a steel tube for added safety. It is also important to follow the rules and regulations set by organisations such as NHRA, IHRA, and SCCA. For example, per NHRA and IHRA rules, any fuel lines inside the car must be sealed from the passenger compartment.
When running fuel lines inside the car, it is recommended to route them through the central tunnel to prevent damage in side-impact collisions or crashes. This is often done on the passenger side, away from the driver. It is also important to keep the fuel lines away from the drivetrain, wheel, and tire of the car. Some people choose to run the lines over the top of the passenger-side inner fender and then down along the curbside of the frame rail and frame connector. This helps to keep the fuel lines away from engine heat, which can bake the fuel and cause vapor lock.
Additionally, when running fuel lines inside the car, it is important to consider the placement of the fuel cell. Some people choose to mount the fuel cell in the trunk or recessed box in the rear floor, but it is important to ensure that it is properly sealed and separated from the driver and passenger compartments. Overall, while running fuel lines inside a car can be done safely, it is important to carefully follow the necessary precautions and regulations to ensure the safety of the vehicle's occupants.
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Using flexible fuel hose to connect the engine and tank
When using flexible fuel hose to connect the engine and tank, there are several factors to consider. The first is the type of fuel being used. For example, if you are using a high-ethanol fuel, you will need a hose that can handle alcohol-blended fuels. Ethanol dissolves some plastics, so it is important to choose a hose that is compatible. Hoses made from polytetrafluoroethylene (PTFE), better known as Teflon, are compatible with ethanol and can handle very high pressure and temperature. Braided hose options are also available, but it is important to check the specifications to ensure compatibility with ethanol and fuel additives.
Another consideration is the length of the hose. It is important to ensure that the hose is not too long, as this can cause kinking and restrict fuel flow. Careful measurement is necessary to avoid this issue. Additionally, when working with the fuel system, it is recommended to relieve the pressure and replace the fuel filter for safety.
The regulations for fuel lines vary depending on the application. For marine use, look for a hose marked with "USCG" or "marine fuel hose". For vehicles, follow the government fuel hose emissions regulations, especially if you plan to use your vehicle in different locations. The state of California, for example, has strict requirements marked with "CARB" (California Air Resources Board). Using a CARB-certified hose can improve fuel economy and resist seepage.
When running flexible fuel lines through the cabin of a vehicle, there are safety considerations to keep in mind. It is recommended to use a steel tube that runs from firewall to firewall, with no openings into the passenger compartment. For added safety, the tube should be painted red and labelled as a fuel line. Some prefer to use a Nicopp line along the passenger side of the tunnel, with a bulkhead fitting on each end and a steel shield over the line where a passenger might kick it.
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Regulations for running fuel lines through the cockpit
Running fuel lines through the cockpit requires adhering to specific regulations to ensure safety. While some older cars, like the Saab 96, had fuel lines inside the cockpit, modern safety standards have introduced stricter rules.
Firstly, it is essential to consult the rule book of your sanctioning body to understand the legal requirements for running fuel lines through the cockpit. These rules can vary depending on the type of racing and the sanctioning organisation.
When running fuel lines through the cockpit, one common regulation is to use a Nicopp line along the passenger side of the tunnel. This line should have a bulkhead fitting on each end, and if there is a passenger seat, it is recommended to place a steel shield over the line to protect it from being kicked. Painting the line red and labelling it clearly as a "fuel line" or "do not cut" is also advised for safety reasons.
In addition, several rule books emphasise the need to encase fuel lines passing through the cockpit in a durable steel or aluminium pipe, heavy-duty conduit, or strong metal plate. This provides an extra layer of protection in the event of an accident. Some regulations also require a complete steel firewall at the front and back of the driver's compartment, sealed off entirely.
It is worth noting that running fuel lines through the cockpit is not without controversy. Some people believe it is unsafe, arguing that a solid metal line in the cockpit can deform and crack open during impact. Therefore, it is crucial to carefully consider the regulations and prioritise safety when making decisions about fuel line routing.
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The safest way to run fuel lines
Running fuel lines can be a dangerous task, and it is important to take precautions to ensure safety. Here are some detailed and direct instructions on the safest way to run fuel lines:
Firstly, it is crucial to disconnect the battery before beginning any work on fuel lines. This helps prevent any accidental ignition sources. Once the battery is disconnected, the next step is to carefully remove the fuel line running from the pump to the carburetor. If the vehicle has been running recently, this line will contain pressurized fuel, so it is important to be prepared with a shop rag to catch any spillage.
When it comes to the fuel lines themselves, there are a few key considerations for safety. Firstly, it is generally recommended to avoid running fuel lines through the driver's or passenger's compartment. In the event of a collision, damage to fuel lines in these areas could pose a significant risk to the occupants. Instead, consider running the lines externally, such as underneath the car along the frame rails. Ensure that the lines are well-protected and securely mounted to reduce the risk of damage.
If running the fuel lines inside the car is unavoidable, there are still ways to mitigate the risks. One method is to use a steel tube that runs from firewall to firewall, with no openings into the passenger compartment. This tube should be painted red and clearly labelled as a fuel line. Alternatively, a Nicopp line can be run along the passenger side of the tunnel, with a bulkhead fitting on each end. If there is a passenger seat nearby, it is advisable to put a steel shield over the line for added protection.
The type of fuel line used is also an important consideration. Standard rubber fuel lines should be avoided, especially on the pressure side of the fuel system, as they can break down over time due to the ethanol content in modern pump fuels. This can lead to leaks, which pose a fire risk. Instead, consider using steel or aluminium lines, which are more durable and safer. Additionally, ensure that any connections or fittings are secure and compatible with the type of fuel line used.
Finally, always follow the regulations and guidelines provided by your sanctioning body or rule book. These guidelines are in place to ensure the safety of both the vehicle and its occupants, so it is important to adhere to them closely.
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Making your own fuel lines
First, it is important to gather the necessary tools and materials. You will need tube bending and flaring tools, which are available from various sources such as Harbor Freight Tools and The Eastwood Company. These tools come in different price ranges to fit different budgets. Additionally, ensure you have the appropriate tubing for fuel lines, which can be steel, stainless steel, or aluminium. You can purchase these materials from suppliers like Classic Tube, which offers rolls of tubing that you can custom bend and flare.
When it comes to the flaring process, it is crucial to achieve a perfect 45-degree double flare on each line end and fitting. This is important to contain the extreme pressures in brake and fuel lines. Start by using the proper die to create an initial bubble flare, and then roll the walls inward to form the 45-degree double flare. Take your time during this process to avoid cockeyed and incomplete flares, which can lead to leakage.
To make the flaring process smoother, it is recommended to use a lubricant at the flaring head and line end. For fuel lines, a low-viscosity engine oil or WD-40 can be used as a lubricant. Before flaring, ensure that your tank is empty or you have a vacuum line intact to prevent gasoline leaks. Additionally, consider using PTFE lines, as they are suitable for all fuels and do not allow the fuel smell to seep through.
When cutting the tubing, it is important to use a good tube cutter to achieve square and burr-free cuts. To prevent fraying of the lines during cutting, you can apply painters tape, masking tape, or duct tape. It is also recommended to put the tape on fairly thin and to cover the braid with tape before cutting. A hose cutter from Summit or a cable cutter from Lowes or Home Depot can make the cutting process quicker and cleaner.
Finally, when installing the fuel lines, you can mark the fittings with different colour tape or labels to ensure proper placement. It is also important to consider the length of the fuel lines, which is typically around 15 feet for most vehicles. By following these steps and taking your time, you can successfully make your own fuel lines and customise your vehicle to your liking.
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Frequently asked questions
Steel or stainless steel hard lines are the most popular choice for running fuel lines. Some prefer to use a Nicopp line, while others suggest aluminium tubes for under the car.
It is important to follow the regulations for running fuel lines, especially in the cockpit of a car. It is generally advised to avoid running fuel lines through the driver's compartment. If you do, use a steel line with no connections, secured with cushion clamps.
It is recommended to use a flexible fuel hose to connect the fuel lines to the engine and the tank. This helps to isolate vibration and movement, making it easier to remove the tank in the future.
You will need the right flaring tool to make your own fuel lines. You can use a MASTERCOOL flaring tool to create a barb connection, or a die to leave the barb rounded instead of sharp.
