Rajan Wilcox
Running a new hard fuel line can be a tricky process, with many factors to consider. It is important to ensure the line is not lower than any part of the frame and that it is a safe distance from the exhaust heat and chassis flex/vibration. The type of material used for the fuel line is also an important consideration, with options including stainless steel, aluminium, rubber, and PTFE. In addition, the use of a filter and the routing of the line, either inside or outside of the frame rail, are key decisions that need to be made. Some trial and error may be required to find the best solution, and it is recommended to take the time to plan the project carefully.
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What You'll Learn
Using a 12-gal RCI aluminium fuel cell
When using a 12-gal RCI aluminium fuel cell, there are several important considerations and steps to follow to ensure a safe and effective fuel system installation. Firstly, it is crucial to select the appropriate fuel cell for your specific application. The RCI 12-gal fuel cell is designed for street use and is compatible with various fuels, including standard gasoline and racing fuels. This versatility makes it suitable for different vehicles, whether you are using it for street driving or track performance.
Before installing the fuel cell, it is important to check if any modifications are needed to ensure a proper fit. Measure the dimensions of your vehicle's fuel tank area and compare them to the fuel cell specifications. In some cases, you may need to make adjustments or add components, such as a fuel pump, to complete the fuel system. Additionally, ensure that the fuel cell meets the safety and performance standards required for your intended use, especially if you plan to use it for racing competitions.
When installing the fuel cell, it is crucial to consider the routing of the fuel lines. Some users have suggested running the lines through the body braces towards the front, and then up the fender well, using bulkhead connectors. It is generally recommended to avoid running fuel lines inside the wheel house area, as a blowout can destroy the lines and potentially ignite the fuel. Instead, consider running the lines outside the frame rails or through frame connectors to provide better protection.
Finally, when connecting the fuel lines, it is important to use compatible and high-quality components. Some users have recommended using braided stainless steel lines or encasing the lines in steel tubing for added protection against rupture. It is also essential to consider the bends and routing of the lines, as tight bends can be tricky and may require specialised tools for bending and routing. Always refer to the manufacturer's instructions and follow safety guidelines when working with fuel systems.
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Running lines through the body braces
Running fuel lines through the body braces of a car can be a tricky process, and there are several factors to consider. The first step is to decide whether to run the lines inside or outside of the frame connectors. Running the lines inside the frame connectors can provide more protection from potential damage, but it is important to ensure that the lines are not too close to the exhaust to avoid heat issues. One way to mitigate this is to use heat wrap or a small aluminium heat shield to protect the lines.
When running the lines outside the frame connectors, it is necessary to go through the rear frame and back through the front frame to the engine compartment. This method can help keep the lines away from the heat of headers and exhaust and protect them from potential rupture due to a failing driveshaft or flexplate failure. However, it is crucial to avoid placing the lines under the connector, as this can make them more susceptible to damage and increase the risk of fuel leakage and sparks.
The type of material used for the fuel lines is also important. Stainless steel lines, for example, require special tools for bending and routing, and it can be challenging to make precise bends without collapsing the tubing. Pre-bent fuel lines can be purchased, saving time and effort, but they may not always fit perfectly and may require test-fitting and adjustments. Additionally, the use of rubber hoses to cover the lines can provide protection and flexibility.
Finally, safety considerations are paramount when running fuel lines. It is essential to ensure that the lines are not lower than any part of the frame and that they are securely mounted to prevent rupture. Proper planning and consideration of factors such as proximity to exhaust heat and chassis flex/vibration are crucial to ensure a safe and effective fuel line installation.
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Using steel braided lines
Braided steel lines are a popular choice for fuel lines in Mopar vehicles. They offer several advantages over traditional rubber hoses, including durability and resistance to fuel additives and ethanol-blended fuels. Braided steel lines are also less susceptible to rust and corrosion, making them a long-lasting option.
When using steel braided lines, it is important to consider the outer diameter, as it may be larger than the original hard line, which can make routing more challenging. Additionally, the compatibility of the braided line with the fuel type is crucial, as not all braided lines are compatible with ethanol-blended fuels. To ensure compatibility, PTFE (Teflon) lined braided hoses can be used, which are also smaller in diameter and can handle ethanol blends.
The process of installing steel braided lines may involve adapting AN fittings to the existing hard lines. This can be achieved by welding a steel bung to the tip of the hard line or using a pipe-to-AN adapter with a brass ferrule. It is recommended to use a flare nut and a 37-degree flare tool for a secure connection. Securing the line at regular intervals is essential to prevent chafing and potential leaks.
When running steel braided lines, it is important to consider the routing carefully. Some prefer to run the lines outside the frame rails to protect them from the heat of headers and exhaust and to reduce the risk of rupture from components like the driveshaft and flexplate. However, for track cars, running the lines inside the frame rails may be necessary to comply with tech inspection rules. In such cases, steel braided lines or encasing the lines in steel tubing of a specified thickness and length is typically required.
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Using a 3/8 stainless steel line
Running a 3/8" stainless steel fuel line in a Mopar can be a tricky process due to the complexity of the bends required. It is recommended to use pre-bent fuel lines because of their length and the number of bends involved. Stainless steel is a durable choice that will not rust and is resistant to fuel, but it can be challenging to bend, so it is best to have the flaring done by a shop.
One option is to use braided stainless steel AN-6 hose for the complete fuel system. It is important to choose a reputable brand, such as Earl's, Russell, or Aeroquip, to ensure compatibility with modern fuels and prevent rotting. The fittings for this type of hose can be tricky, so it is essential to use the right tools. Some companies offer stainless compression fittings that can be attached to a pipe thread without any modifications to the steel line.
Another consideration is the use of a return line. While some people in Canada with similar setups do not think it is necessary, it may be a good idea to include one for added peace of mind. It is also worth noting that soft lines are generally not recommended due to the potential for fuel additives to affect their long-term resistance.
When running the fuel line, it is crucial to avoid the wheel house area, as a blowout can destroy the fuel lines and cause a fire. Instead, consider running the line through the frame and subframe connectors, ensuring that it is securely mounted to protect against fuel line rupture.
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Using a 5/16 fuel line
Running a 5/16 fuel line is a great option for your Mopar. It is important to ensure that the fuel line is rated for fuel injection and is ethanol-proof. You can identify this by looking for green printing on the line, which indicates that it is a Gates fuel-injected "rated" hose.
One recommended option is the PRO 1 Fuel Line Hose with a 5/16-inch inside diameter and 25 feet in length. This hose is made in the USA and is suitable for most common liquid fuels, including ethanol gasolines. It is constructed with NBR rubber and has a high-pressure rating of 300 PSI. The hose is flexible, easy to work with, and reinforced with a braided material for added strength.
Another option is to use a 5/16" MIL6000 hose, which is commonly used in aircraft applications and can handle a variety of liquids. This hose can withstand high and low temperatures, ranging from -40° to 250°F, and meets or exceeds US military specifications. It features an oil-resistant tube and is reinforced with mildew-resistant yarn for added durability.
When installing a 5/16 fuel line, it is important to use appropriate clamps to secure the hose and prevent leaks. Some recommended clamps include the spring clamps that Mopar used 55 years ago, as well as the squeeze-style clamps from NAPA.
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Frequently asked questions
It is important to ensure that the line is not lower than any part of the frame, and that it is not placed too close to the exhaust heat and chassis flex/vibration. It is also recommended to avoid running the fuel line in the wheel house area to prevent potential damage from a blowout.
A tubing cutter, hand bender, flaring tool, tubing adapter, and hard line tubing are required. It is recommended to buy the hard line tubing in a 25-foot roll or more to have extra around.
It is suggested to run the line along the inside of the frame connector and attach it with clips and self-tapping screws. Another option is to run it through a hole in the torsion bar crossmember. Protecting the line from exhaust heat with a shield or wrap is also recommended.
