Rajan Wilcox
Nylon fuel lines are a popular choice for car enthusiasts, offering a flexible and durable alternative to metal lines. With nylon, you can easily bend and manoeuvre the tubing to fit your vehicle's unique specifications. Nylon is also resistant to rot and ethanol, making it a long-lasting option. However, some car owners are hesitant to use nylon due to concerns about its performance under high pressure. When attaching a nylon fuel line to a steel line, it's crucial to ensure the inner diameters match to prevent pressure backups and potential leaks. While some opt for boiling water to soften the nylon, others use hair dryers or heat guns with caution. The right fittings, clamps, and tools are essential to ensure a safe and secure connection.
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What You'll Learn
Nylon vs metal fuel lines
Nylon fuel lines are a popular alternative to metal fuel lines, especially for those seeking an option that is easy to work with and long-lasting. Nylon fuel lines are known for their durability, flexibility, and ease of installation. They can be bent by hand and are less likely to leak compared to metal lines. Additionally, nylon lines are resistant to rot and ethanol. However, nylon lines may not be suitable for all applications. Some users have expressed concerns about their rigidity, especially when trying to work or clean around them. They can be challenging to attach to steel lines and may not be ideal for sharp curves due to the risk of kinking.
Metal fuel lines, on the other hand, are considered the traditional choice for fuel lines. They are known for their strength and durability. Metal lines, such as stainless steel, are easy to fabricate and bend, making them a preferred option for custom applications. Metal lines are also good heat dissipaters, which can help move fuel quickly. However, metal lines can be more difficult to work with than nylon, especially when it comes to fabrication and bending. Metal lines may also be more expensive than nylon lines, and they are susceptible to rust and corrosion.
When deciding between nylon and metal fuel lines, it is important to consider the specific application and requirements. For example, nylon lines may be preferred for their flexibility and ease of installation, while metal lines may be chosen for their strength and heat dissipation properties. Additionally, cost and long-term durability may be factors to consider. It is worth noting that both options have their advantages and disadvantages, and the best choice will depend on the specific needs of the vehicle and the user's preferences.
In terms of attaching nylon to metal fuel lines, it is important to ensure a secure and safe connection. Some methods include using a compression fitting with a cap nut and ferrule, flare nut and cap fittings, or a barbed splice fitting. It is crucial to ensure that the inner diameters of the lines are similar to avoid changes in flow characteristics and pressure increases. Additionally, it may be beneficial to use silicone or motor oil to help attach the lines.
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Attaching nylon to steel lines
Nylon tubes usually use a compression fitting with a cap nut and ferrule. Flare nut and cap fittings are cheap and a tubing flare end kit can be bought for less than $20. You can find metal-to-plastic compression fittings, but you will have to cut and flare the steel line in some cases.
When attaching nylon to steel lines, it is important to ensure that the inner diameters of the two lines are the same. If the nylon line is smaller, it will stretch over the end of the steel line. This can be achieved by using a large Phillips-head screwdriver to pry the nylon line side to side until it stretches. However, nylon lines are not very forgiving, especially if they are rigid, and stretching them too much can cause them to kink and block the flow.
To attach the nylon line to the steel line, some people recommend heating the nylon tubing and pushing it onto the steel tubing. However, this method may not work if the steel tubing is much larger than the nylon tubing. Another option is to use a barbed splice fitting, which is specifically designed for hard nylon lines. The barbed fitting can be heated with boiling water or a hairdryer to soften the nylon and allow it to slide over the barbs.
It is important to note that nylon fuel lines are generally rated at thousands of PSI, but some types of nylon may not have the burst strength for fuel injection systems. Therefore, it is crucial to get the proper type of nylon line and ensure that it is attached correctly to prevent leaks and potential safety hazards.
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Using boiling water to soften nylon
Nylon is a popular choice for fuel lines as it is easy to work with, can be bent by hand, and is resistant to rot and ethanol. It is also used because it is cheap and easy to cut with a baby hacksaw. However, nylon is not very forgiving, especially if it is the rigid type, and it is important to ensure that the inner diameters of the lines are the same to avoid changes in flow characteristics and an increase in pressure.
Nylon has a high melting point due to the chemical feature known as an amide group, which creates a very polar group that gives rise to a relatively strong attraction between the nylon chains. This attraction is known as a hydrogen bond, which is also responsible for water's high boiling point. This similarity in bonding types creates an unusual affinity between water and nylon, and at equilibrium, nylon can hold approximately 1.5-2% of its weight in water.
When water molecules become absorbed into the nylon matrix, they attach themselves to the amide groups in the nylon chains, forcing the nylon chains farther apart. This reduces the attractive forces between the chains and lowers the glass transition temperature. Above the glass transition temperature, an unfilled nylon loses most of its room-temperature stiffness and becomes increasingly flexible. This is why most nylon materials have two data sheets—one for dry material and one for conditioned polymer.
Therefore, to soften nylon tubing, one can use boiling water to increase its moisture absorption and reduce its stiffness. However, it is important to note that even with boiling, the nylon might not become soft enough to work with. In such cases, additional heat from a hair dryer might be necessary.
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Cutting nylon cleanly
When cutting nylon cleanly, it is important to use a sharp tool. This could be a razor blade or a baby hacksaw, for example. You can also use standard woodworking and metalworking tools, such as band and circular saws. However, the blades of these tools should be offset to avoid excess heat buildup, which can cause the cut to become malformed.
The sharpness of the tool is critical for clean cuts. If you are using a tap, for example, the sharpness of the tap is crucial. Taps used on metal are not interchangeable with cast nylon. High-speed taps should be oversized by approximately 0.002"-0.005".
It is also important to consider the speed at which you are cutting. The turning speed should be adjusted based on the type of cast nylon used and the number of cuts needed for the project. Generally, you will cut at the same speed as a free-cutting material (between 600-900 ft/min). Depending on the depth of the cut, you will cut at 0.003-0.015” per revolution.
Before cutting, it is important to fully secure the cast nylon pieces with clamps or by hand. Most projects are milled at 1000 feet/min, but heavier cuts are milled at 9 feet/minute.
Additionally, it is worth noting that nylon fuel lines are generally rated at thousands of PSI. However, some nylon does not have the burst strength for fuel injection systems, so it is important to get the proper type.
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Nylon compression fittings
Nylon fuel lines are a great choice for your vehicle due to their durability and ease of use. They are resistant to rot and can be easily bent by hand, making them a popular option for fuel lines.
When it comes to nylon compression fittings, there are a few methods you can use to ensure a secure connection. One common method is to use a compression fitting with a cap nut and ferrule. This type of fitting typically includes a flare nut and cap, which are inexpensive and readily available. A tubing flare end kit can be purchased for less than $20 and will provide you with the necessary components for the connection.
To attach the nylon fuel line to a steel fuel line, it is important to ensure that the inner diameters of both lines are the same. This is crucial to maintain consistent flow characteristics and prevent an increase in pressure that could lead to a safety hazard. You can use a large Phillips-head screwdriver to stretch the smaller braided hose over the larger steel hose, working it side to side to achieve the necessary stretch. Additionally, spraying silicone or motor oil on the steel tube can aid in the process.
Another method for connecting nylon fuel lines is by using barbed fittings. These fittings are designed specifically for hard nylon lines and can be purchased from parts stores. However, it is important to note that simply getting the line into boiling water may not be enough to soften it sufficiently to attach to the fitting. You may need to use additional tools, such as a hairdryer, to provide extra heat and ensure a secure connection.
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Frequently asked questions
Nylon tubes usually use a compression fitting with a cap nut and ferrule. The inner diameters of the two lines should be the same, or the flow characteristics might change and pressure will increase in the smaller diameter line. You can use a large Phillips-head screwdriver to stretch the smaller line over the end of the steel line.
Some options include:
- Buying a Dorman kit and pressing the new fitting on using a clamp block.
- Heating the line with a heat gun (although this can be dangerous if done inside a car with the fuel tank open).
- Heating the line with boiling water (although this may not heat the line enough).
- Using a hairdryer to heat the line.
Nylon fuel lines are easy to work with and can be bent by hand. They are also resistant to ethanol and will never rot. They are also cheaper than metal lines.
