Rajan Wilcox
Metal fuel lines are used to connect different parts of a vehicle's fuel system, such as connecting steel fuel lines to rubber fuel hoses. It is essential to secure these connections to prevent fuel leaks. Various methods can be used to tie into a metal fuel line, including using metal wire, bread twist ties, or specialised clamps. Some people solder a bit of paper clip onto the fuel tube and tie it, while others use compression fittings or flare the hard line and use clamps or fasteners. The choice of method depends on the specific application and personal preference.
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What You'll Learn
Using wire scraps
When it comes to tying into a metal fuel line, one method that can be used involves utilising wire scraps. This approach ensures a secure connection and prevents the fuel line from coming loose. Here's a step-by-step guide on how to use wire scraps effectively:
Firstly, it is important to select the appropriate wire type and thickness. Some individuals recommend using thin-gauge wire, such as 7-strand wire (7/050 wire) composed of seven strands of .5mm copper wire. This type of wire can be sourced from electrical wire scraps. Alternatively, you can use a single strand of 8-core data cable or stainless steel safety wire. If you opt for safety wire, a spool with a thickness of 0.020" to 0.030" is recommended.
Next, you'll want to cut and strip the wire to the desired length. Ensure you have enough wire to wrap around the fuel line a few times. Using a pair of wire cutters or side cutters, trim the wire to size. Then, use wire strippers or a similar tool to carefully strip away any insulation or coating on the wire, exposing the bare metal.
Now, you're ready to start the tying process. Position the wire behind the fuel line connection, ensuring any barbs or connectors are in place. Wrap the wire securely around the fuel line, making sure to leave a little slack to work with. Cross the wire behind the connection and use a pair of needle-nose pliers to grab and hold the wire in place.
At this point, you can begin tightening the wire. Rotate the wire a few times, creating a secure seal. You can do this by holding the wire with the pliers and twisting it, or by holding the fuel line and rotating the pliers, depending on your preference. Ensure the wire is tight enough to prevent leaks but be careful not to over-tighten, as this may cause the wire to break.
Finally, trim off any excess wire using side cutters or wire cutters. Ensure that any sharp edges are removed to prevent potential damage to the fuel line or surrounding components. By following these steps and utilising wire scraps, you can effectively tie into a metal fuel line, creating a secure and reliable connection.
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Soldering
When soldering metal fuel lines, it is important to consider the type of metal being used, as this will determine the solder and tools required. For instance, silver solder is recommended for stainless steel tubing, as it forms a stronger joint than conventional lead/tin solder and has better fatigue resistance. Regular plumbing solder is not suitable for this purpose as it is not hard enough to withstand the vibrations that the line is subjected to in use.
Before soldering, the metal surface must be clean and bare. This can be achieved by scuffing the metal with a Scotch pad or light sandpaper, and then wiping it with acetone or toluene. It is also important to ensure that there is enough unsupported steel line or rubber hose to allow for rotational engine movement.
When soldering fluid-tight joints in metal tubing, a torch is required to generate the necessary heat. A simple Burnz-O-Matic torch is one option that has been used with good results. The amount of heat required will depend on the type of metal tubing being used, with stainless steel requiring very high temperatures to form a good solder joint.
It is important to note that acid core solders and muriatic acid are not recommended for use with silver solder, as they can cause failure if the metal is not properly prepared. Instead, a paste flux such as Handi-Flux can be used to achieve excellent results.
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Clamping
Types of Clamps:
Several types of clamps can be used on fuel lines, each with its advantages and disadvantages. Some common types include:
- Spring clamps: These are easy to install and remove, but may not provide the most secure connection.
- Hose clamps (regular or screw-type): These are commonly used, but care must be taken not to overtighten, as they can pinch the hose and cause leaks.
- Pinch clamps: These provide a secure connection but are more challenging to install and remove, often requiring side-cutters.
- Ear clamps: These are similar to pinch clamps and offer a stable connection.
- Zip ties: Plastic zip ties are a simple and affordable option, but they may not be as durable or secure as metal clamps.
- Oetiker clamps: These are solid screw-type clamps that provide a secure connection but can be challenging to remove and reuse.
Materials:
The choice of clamping material is crucial, especially for metal fuel lines. Some common materials used include:
- Metal wire: Stainless steel wire, such as safety wire, is commonly used to tie off fuel line connections. It is strong, durable, and can be twisted tightly to secure the connection.
- Bread tie wire: Some people use the twisty tie wire that comes with a loaf of bread, leaving the plastic sheath on to prevent fuel line cuts.
- Picture hanging wire: Unbraided stainless steel picture hanging wire can be used as a cheap and effective alternative.
- Copper wire: Electricians may use strands of copper wire from scrap cable, providing a strong and flexible connection.
Techniques:
The proper technique for clamping a fuel line involves more than just tightening the clamp. Here are some key considerations:
- Positioning: The clamp should be positioned at the midpoint of the male fitting inserted into the hose.
- Tightness: The clamp should be snug enough to deform the hose slightly but not overtightened to the point of cutting into the hose or causing leaks.
- Temperature and Pressure: Ensure the hose is rated for the temperature and pressure of the fuel system. The hose should be UV-stable if exposed to direct sunlight.
- Maintenance: Some clamps, like the Oetiker clamps, may be challenging to remove and reuse, requiring special tools and potentially causing maintenance headaches.
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Compression fittings
For fuel lines, it is recommended to use carbon steel or stainless steel for alcohol fuels. Brass fittings should be avoided when they might be exposed to methanol. It is also possible to use nylon for a replacement fuel line. However, caution should be exercised when using anything but steel as nylon can melt.
When using nylon lines, it is important to soften the line with hot water and carefully push it onto the barbs. The nylon will push on very hard, and when it hardens, it should be good to go without the need for clamps. It is also possible to use a fuel line repair kit, which includes a steel line and a nylon line, to effectively hold and seal the connection all at once.
For steel fuel lines, it is recommended to use a flaring tool to create a 37-degree flare in the line to adapt to AN hardware. This can be done with a cheap double flaring tool from Harbor Freight or a more expensive, high-quality mil-spec flare tool. Another option is to use fittings from a company called Swagelok, which uses a double ferrule that forces itself into the metal of the tube, creating a leak-proof seal.
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Flaring
When flaring metal fuel lines, it is essential to ensure that the line ends are free of any burrs or imperfections. This can be achieved by using a hacksaw or a tubing cutter, although it is important to note that a tubing cutter will work-harden stainless steel, making it more challenging to achieve a proper flare. After the initial cut, a flaring tool can be used to create a "bubble" on the end of the tube, which will help to secure the connection and prevent leaks.
For fuel lines, it is recommended to use a lubricant at the flaring head and line end to ensure a smooth process. A low-viscosity engine oil or WD-40 can be used as a suitable lubricant for this purpose. It is also important to note that fuel lines require a double 45-degree flare to contain the pressure within the system.
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Frequently asked questions
It is good practice to tie off your metal fuel line connections with metal wire to prevent them from coming loose. You can use stainless steel wire, which is available at most hardware stores.
The ideal wire for this purpose would be a thin gauge, stainless steel wire. It is important to ensure that the wire is thin enough to be effective, but also strong enough to not break when twisted.
To connect a metal fuel line to a rubber hose, you can slip the hose over the pipe and use fuel line clamps. For a more secure connection, you can flare the hard line, use an AN nut and sleeve, and then mate it to a pushlock fitting.
Yes, it is possible to splice a metal fuel line. You can use compression fittings if the outside diameter of the tube is clean. However, it is important to consider the impact of cold and heat fluctuations on the fittings.
