Ameer Randolph
Flaring is a process used to create a 45-degree or 37-degree flare on the end of a rigid tube, which is used for fuel lines. There are a variety of tools available for flaring fuel lines, including the Swagelok brand, which produces compression fittings. Flaring aluminium fuel lines is a cheap and easy process, but it may not be the most practical option in the long run.
| Characteristics | Values |
|---|---|
| Flare angle | 45-degree flare, 37-degree flare |
| Coating | Copper-coated steel tubing |
| Installation | Neat and secure installation |
| Maintenance | Requires virtually no maintenance |
| Tooling | Fuel line flare tool, fuel line bending tool, fuel line clamp tool |
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What You'll Learn
Flaring aluminium fuel lines
To start the flaring process, you need to cut the end of the tube squarely and deburr it. Then, slip an AN818 nut and an AN819 sleeve onto the tube. Next, push the tube into the tool until it hits the stop, then clamp it into place. It is important to rotate the flare so that you get an even face.
It is worth noting that aluminium and alcohol do not mix well. If you are using aluminium fuel lines, you should be aware that the lines can develop corrosion from methanol over time. This is a common issue for racers who use methanol and do not clean out their fuel systems regularly.
Additionally, metal lines should never be placed in a position where they are likely to conduct electricity. Lines routed near batteries need to be protected. Rigid fuel lines that run in the engine compartment should be protected with firesleeve or a similar material.
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Using a fuel line flare tool
Flaring an aluminium fuel line is a cheap and easy process, but it may not be the most practical option in the long run.
To use a fuel line flare tool, start by cutting the end of the tube squarely and deburring it. Then, slip an AN818 nut and an AN819 sleeve onto the tube. Next, push the tube into the tool until it hits the stop, and then clamp it into place. This will create a 45-degree flare, which is not the recommended 37-degree flare used for aviation. However, there are tools available that can create a 37-degree flare, such as the Surseat flare lapping tool, which can be used on brake and fuel lines. This tool removes irregularities in the flare and hones it to a perfect angle to enable the tube to seat with the fitting.
The Eastwood Hydraulic Flaring Tool is another option that can be used to produce OE-precision brake and fuel line flares in steel and soft-metal tubing. It creates 45-degree single and double flares and works on a variety of tube diameters.
It is important to note that metal lines should never be placed in a position where they are likely to conduct electricity. Lines routed near batteries need to be protected. Rigid fuel lines that run in the engine compartment should be protected with firesleeve or a similar material.
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Protecting metal lines from electricity
Metal lines should never be placed in a position where they are likely to conduct electricity. Lines routed near batteries need to be protected. Rigid fuel lines run in the engine compartment should be protected with firesleeve or a similar material, just as flexible lines would. A neat and secure installation should give you many years of reliable service requiring virtually no maintenance.
Flaring is a process used to protect metal lines from electricity. It is important to start the flaring process with a squarely cut and deburred end. Then slip an AN818 nut and an AN819 sleeve onto the tube. The next step is to push the tube into the tool until it hits the stop, then clamp it into place.
It is recommended to use a 37-degree flare for aviation. However, some tools produce a 45-degree flare. Compression fittings are also available under the Swagelok brand. These fittings are handy to use, but more expensive and heavier than AN fittings. They have their place, but most builders will not use them because of these shortcomings.
When flaring aluminium fuel lines, it is important to make sure that your cut is spot on, and to rotate the flare, so you get the flare to have a good even face. Aluminium is not very practical in the long run as it does not live well with alcohol.
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Using compression fittings
Compression fittings are available under the Swagelok brand. They are handy to use, but they are more expensive and heavier than AN fittings. They are not commonly used by builders because of these shortcomings.
To use compression fittings, start the flaring process with a squarely cut and deburred end. Then slip an AN818 nut and an AN819 sleeve onto the tube. The next step is to push the tube into the tool until it hits the stop, then clamp it into place. Make sure that your cut is spot on, and rotate the flare, so you get the flare to have a good even face.
It is worth noting that metal lines should never be placed in a position where they are likely to conduct electricity. Lines routed near batteries need to be protected. Rigid fuel lines run in the engine compartment should be protected with firesleeve or a similar material, just as flexible lines would.
Aluminium is not a very practical choice in the long run. It is cheap and easy, but it does not live well with alcohol.
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Flexible hoses
When it comes to flexible hoses, there are a few things to consider when choosing the right flare for your aluminium fuel line. Firstly, it's important to ensure that your cut is precise and even, as this will affect the quality of the flare. You can use a bundy tube or copper-coated steel tubing to create the flare, but aluminium will also work.
One important consideration when flaring aluminium fuel lines is the issue of corrosion. Over time, aluminium can develop corrosion from methanol, so it's important to be mindful of this and take steps to prevent or mitigate it. For example, using a coating on the carb parts can help to delay the onset of corrosion.
Another factor to keep in mind is the angle of the flare. A 45-degree flare is commonly produced, but for aviation purposes, a 37-degree flare is recommended. This is something to be aware of when choosing the appropriate flare for your application.
To attach a flexible hose to the end of a rigid tube, it is recommended to roll a bead into the end of the tube. This helps to secure the hose and clamp it in place. Inexpensive bead rollers are available for this purpose, and the most common size for fuel lines is 3/8-inch .035-wall tubing.
By following these guidelines and best practices, you can ensure a neat and secure installation that will provide many years of reliable service with minimal maintenance required.
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Frequently asked questions
You should use a 45-degree flare.
No, a 37-degree flare is used for aviation.
The end of the tube should be cut squarely and deburred.
It is good practice to roll a bead into the end of the rigid tube to help secure the hose and clamp.
Yes, compression fittings are available under the Swagelok brand. However, they are more expensive and heavier than AN fittings.
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