Mercedes Mullins
The size of a fuel line is an important consideration when it comes to fuel pumps. While a larger line may be more expensive, it can be beneficial for certain types of fuel and may be useful if you decide to install an electric fuel pump system in the future.
| Characteristics | Values |
|---|---|
| Fuel line size | 1/2" fuel line is too big for a mechanical fuel pump |
| Fuel line material | Steel is stronger than aluminium |
| Fuel type | Ethanol requires 30% more fuel than gasoline to generate the same HP |
| Fuel pressure | A bigger pump, higher pump voltage and/or increasing the line size can increase fuel pressure |
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What You'll Learn
Fuel line sizing
In-line fuel pump manufacturers often recommend a fuel line diameter that works best with their pumps to prevent starving the pump. This diameter may not be the same as the size of the outlet line. The type of fuel used also affects the required fuel line size. Ethanol requires 30% more fuel than gasoline to generate the same horsepower, while methanol requires double the amount. As a result, the fuel lines for these fuels should be one to two sizes larger than the gasoline requirement.
When choosing a fuel line material, steel tubing is a common choice due to its strength and durability. It is less prone to vibration and flex issues compared to aluminium tubing, making it a better option for street-driven cars.
While a larger fuel line can provide benefits, such as accommodating future upgrades to an electric fuel pump system, it may also be more expensive and may not be necessary for all applications. It is important to consider the specific requirements of the engine and fuel system when determining the appropriate fuel line sizing.
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Fuel line materials
Fuel lines can be made from a variety of materials, including metal, rubber, braided, and plastic. Metal fuel lines are the most common and are usually made from stainless, aluminium, or coated steel tube. Metal is the best material for fuel lines as it is resistant to wear and tear and is not prone to cracking or deterioration. However, it can be difficult to fabricate.
Rubber fuel lines are more flexible and easier to install, but they can become hard and brittle over time. They are typically connected using standard barbed fittings and fuel line hose clamps. Braided fuel lines are also flexible but are prone to leaks if the braid becomes damaged. PTFE-lined fuel lines are very durable and resistant to wear, heat, and chemical damage.
Plastic fuel lines do not perish and are lighter than metal tubing, but they melt at lower temperatures and cannot be repaired as easily. Steel pipes are strong and cheap but can corrode, causing fuel leaks. Aluminium has more fatigue issues than steel. Copper fuel pipes are easy to fit and repair but are heavy and expensive.
NBR rubber fuel lines are flexible, durable, and have a long service life. They can be used with diesel, biodiesel, gasoline, oil, grease, water, and air.
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Fuel line pressure
The size of the fuel line you need depends on the pump and the type of fuel you are using. Many in-line fuel pump manufacturers recommend a fuel line diameter that works best with their pumps. This prevents starving the pump and is not necessarily the size of the outlet line. For example, ethanol will require about 30% more fuel than gasoline to generate the same HP, so when designing a fuel line system for ethanol, go one or two sizes larger than the gasoline requirement.
The return lines, which are the fuel lines after the regulator, can generally be one size smaller than the feed line. A 3/8”id fuel line can easily support 600 HP given sufficient “pump head”. Given a big enough pump, a 3/8” steel line could support 1000 HP. The simple way to know is to install an electronic fuel pressure gauge. If the pressure falls as the engine RPM’s go up, you need more pump head. More pump head can be achieved with a bigger pump, higher pump voltage and/or increasing the line size.
Aluminium line has more fatigue issues, whereas steel has less reason to go wrong.
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Fuel type
The size of the fuel line you need depends on the type of fuel you're using. Ethanol requires 30% more fuel than gasoline to generate the same HP, and methanol requires double the amount of fuel. For these fuels, you should go one or two sizes larger than the gasoline requirement.
A 3/8" fuel line can support 600 HP with sufficient "pump head". More pump head can be achieved with a bigger pump, higher pump voltage, and/or increasing the line size. A 3/8" steel line could support 1000 HP with a big enough pump.
A 1/2" fuel line is considered overkill for a mechanical fuel pump, but it would be useful if you decide to install an electric fuel pump system later on.
Aluminum tubing is not recommended for a street-driven car due to vibration and flex possibilities. Steel tubing is a better option as it is stronger and has less reason to go wrong.
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Fuel line return lines
The size of the fuel line is an important consideration when it comes to fuel pump performance. A fuel line that is too large for the pump can cause issues, such as vibration and flex, particularly with aluminium tubing. Steel tubing is often recommended as it is stronger and less prone to fatigue.
The return lines, which are the fuel lines after the regulator, can generally be one size smaller than the feed line. This is because the return lines are not pressurised.
When determining the appropriate size for a fuel line, it is important to consider the pump head, which is the amount of pressure the pump can generate. A larger pump, higher pump voltage, or increased line size can all contribute to more pump head. An electronic fuel pressure gauge can be used to measure pump head; if the pressure falls as the engine RPMs increase, more pump head is needed.
The type of fuel also plays a role in fuel line sizing. For example, ethanol requires about 30% more fuel than gasoline to generate the same horsepower, while methanol requires double the amount. When designing a fuel line system for these alternative fuels, it is recommended to go one or two sizes larger than the gasoline requirement.
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Frequently asked questions
It will work OK, although it is somewhat of an overkill.
Aluminium has more fatigue issues and is more prone to vibration and flex.
Steel has less reason to go wrong and is much stronger, especially at the ends where it is joined to other components via flaring or compression fittings.
Many in-line fuel pump manufacturers recommend a fuel line diameter that works best with their pumps. This prevents starving the pump and is not necessarily the size of the outlet line.
Install an electronic fuel pressure gauge. If the pressure falls as the engine RPMs go up, you need more pump head.
