Sylvie Willis
Fuel line sizing is an important consideration when dealing with high-horsepower applications. A common question is whether the fuel line size needs to be increased to support higher horsepower. For example, a fuel line with a nominal 3/8 inner diameter (ID) can easily support 600 HP with sufficient pump head. With a large enough pump, a 3/8 steel line could even support 1000 HP. However, it is important to consider factors such as the type of fuel, pressure drop, and flow rate to determine the appropriate fuel line size. The key to sufficient fuel supply is pumping power, and external fuel pumps require careful consideration of fuel line size to avoid starving the pump for fuel.
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What You'll Learn
A 3/8 steel line can support 1000 HP
A 3/8 steel fuel line can support 1000 HP, but it depends on a few factors. The size of the fuel line is just one consideration when it comes to achieving sufficient fuel supply to support 1000 HP. Other key factors include the pumping power, the viscosity and surface tension of the liquid being pumped, and the fittings and bends in the fuel line.
For example, a 3/8" steel fuel line can experience a pressure drop of around 5 psi at 1320 HP, which may be acceptable depending on the required fuel rail pressure. Additionally, the type of pump can also play a role, as a big mechanical pump may not perform well with a small line, while an electric pump that pushes the fuel may handle it better.
Chevy engineers have stated that a 3/8" fuel line can feed enough gasoline to support 2200 horsepower. However, some users have reported having trouble with a 3/8" line around 500-525 HP (flywheel HP), while others have achieved up to 680 hp with a 3/8" sending unit and BG mechanical fuel pump.
To determine if a 3/8" steel fuel line can support 1000 HP in a specific application, it is recommended to install an electronic fuel pressure gauge. If the pressure falls as the engine RPM increases, it indicates the need for more pump head, which can be achieved through a bigger pump, higher pump voltage, or increasing the line size.
In summary, while a 3/8" steel fuel line has the potential to support 1000 HP, it is important to consider other factors such as pumping power, liquid properties, and fuel line fittings to ensure optimal performance and avoid any issues with fuel supply.
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Return lines can be one size smaller than the feed line
When it comes to fuel lines, it's important to consider the system's requirements and potential restrictions. The size of the fuel line plays a significant role in the overall performance of the engine. While the feed line, also known as the supply or suction line, is crucial for delivering fuel at the correct flow rate and pressure, the return line can generally be one size smaller.
The feed line is responsible for transporting fuel from the tank to the engine, and it needs to be large enough to accommodate the required flow rate. On the other hand, the return line, which sends excess fuel back to the tank, can typically be smaller in diameter. This is because the return flow is usually less than the total fuel flow, and a smaller line can help save space and costs for the owner.
However, it's important to note that the return line must still be sized correctly to avoid creating back pressure on the regulator, which can impact fuel flow and pressure. Additionally, the length of the fuel lines and the type of engine (carbureted or EFI) should be considered when determining the appropriate fuel line diameter.
In the case of high-performance engines, such as those in the 1000-1500 HP class, larger lines may be necessary to accommodate higher flow rates and longer runs. It's also worth mentioning that the type of fuel can impact the required fuel line size. For example, ethanol and methanol require larger fuel lines compared to gasoline.
When modifying fuel lines, it's always a good idea to refer to manufacturer guidelines and seek advice from professionals or mechanics to ensure that any changes made are safe and suitable for your specific vehicle.
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A bigger pump can support a 3/8 steel line for 1000 HP
When it comes to high-horsepower applications, one common question is whether a fuel line needs to be increased in size to support a certain horsepower. For instance, can a 3/8" fuel line support 600 HP, or does it need to be increased to 1/2"? The answer is that a 3/8" fuel line can indeed support 600 HP, given sufficient "pump head".
Similarly, a bigger pump can support a 3/8" steel line for 1000 HP. To know if you need more pump head, you can install an electronic fuel pressure gauge. If the pressure falls as the engine RPM increases, you need more pump head. This can be achieved with a bigger pump, higher pump voltage, or by increasing the line size. However, it's important to first check if a dirty fuel filter is causing the pressure to fall.
The key to sufficient fuel supply is pumping power. A 3/8" steel line can support 1000 HP at a BSFC of .5. The pressure drop at 1320 HP through a 3/8" steel line might be around 5 psi.
It's worth noting that when using an external fuel pump, the line size is important. If the line is too small, the pump can be starved for fuel. Many aftermarket pumps will list the required line sizes. If your pump does not, you can use a basic guideline table to determine the appropriate size. It's recommended to install a 100 Micron In-Line Fuel Filter between the tank and the pump, and to ensure the pump is as close to the tank as possible, below the outlet, so that gravity feeds fuel to the pump.
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External fuel pumps can be starved for fuel if the line is too small
When using an external fuel pump, it is important to ensure that the fuel line is the correct size. If the line is too small, the pump can be starved for fuel. This is because the pump requires a certain amount of fuel to function properly, and a line that is too small can restrict the flow of fuel, leading to fuel starvation.
There are a few things to consider when determining the appropriate size of the fuel line. Firstly, the diameter of the line is important. A fuel line with a larger diameter will be able to deliver more fuel to the pump than a line with a smaller diameter. For example, a 3/8" steel line can support 1000 HP, while a 1/2" line can support higher HP.
Another factor to consider is the type of fuel being used. Different types of fuel have different requirements. For example, ethanol requires about 30% more fuel than gasoline to generate the same HP, while methanol requires double the amount of fuel. As a result, when designing a fuel line system for these fuels, it is recommended to use a line that is one or two sizes larger than the gasoline requirement.
In addition, the location of the fuel line can impact the size that is needed. The fuel line after the pump can typically be the next smaller size. Similarly, return lines, which are the fuel lines after the regulator, can generally be one size smaller than the feed line.
It is also important to consider the recommendations of the fuel pump manufacturer. Many in-line fuel pump manufacturers suggest a fuel line diameter that works best with their pumps. Following these recommendations can help ensure that the pump receives the proper amount of fuel and prevent issues such as fuel starvation.
Finally, it is worth noting that a clogged or failing fuel pump can also lead to fuel starvation. This can be caused by a variety of factors, including a clogged filter, sediment or other particles in the fuel line, or a malfunctioning relief valve. Regular maintenance and the use of high-quality fuel can help prevent these issues and ensure the proper functioning of the fuel pump and fuel line.
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Steel braided hoses are not recommended for fuel lines
A 3/8" steel line can support 1000 HP, given a big enough pump. However, steel braided hoses are not recommended for fuel lines. The primary function of the steel woven outer casing is to protect the rubber hose inside from damage and abrasion. Braided lines can degrade from the inside out, and it is difficult to inspect the inner liner for failure.
Some people have reported issues with fuel leaking or weeping through the steel braid in the middle of the hoses. This is due to the inner rubber failing and allowing fuel to leak through. The good stuff that doesn't degrade uses Teflon (PTFE) internals, but most braided hoses for sale are not made of this material and will include a disclaimer not to use them for fuel.
The problem with rubber fuel hoses is that they are putting more and more ethanol in fuel. Ethanol is an alcohol-based liquid that dries out the rubber over time. The alcohol reacts with the rubber, drying out the elastomers and causing the hose to become brittle and eventually crack, emitting fuel vapour. Even with low exposure to heat, steel braided lines might absorb heat faster than other materials, which could contribute to this issue.
While steel braided hoses might be suitable for track cars or racing, for everyday cars that are stock, standard fuel lines are recommended. A rubber or combination of rubber and hard lines should be sufficient.
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Frequently asked questions
A 3/8”id steel fuel line can support 1000 HP given a big enough pump.
A bigger pump can achieve more pump head, which is needed if the pressure falls as the engine RPM’s increase.
Pump head can also be achieved with a higher pump voltage and/or increasing the line size.
