
Fuel lines are an essential component of any vehicle, and choosing the right size and type of tubing is crucial for optimal performance and safety. Fuel lines can vary in size and material, and the selection depends on factors such as the vehicle's engine, performance requirements, and regulations. The most common materials used for fuel lines include metal, rubber, nylon, and braided hoses, each with its advantages and disadvantages in terms of durability, flexibility, and resistance to fuel vapors. The size of the tubing can range from 6mm to 19mm in internal diameter, and it is important to ensure the fuel line is not too small, especially when using an external fuel pump, to avoid starving the pump for fuel.
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What You'll Learn
- Fuel line repairs on a budget: Nylon Tubing is cheaper than rubber fuel hose
- Fuel pump proximity: The pump should be close to the tank and below the outlet
- Fuel type: When using E85, alcohol, methanol, etc., use a bigger fuel line
- Hose fitting: JIC/AN fittings are common and sized by thread and hose size
- Hose material: PTFE Lined Hose is the best soft hose, but requires special fittings

Fuel line repairs on a budget: Nylon Tubing is cheaper than rubber fuel hose
When it comes to fuel line repairs, cost is a significant factor to consider. While several factors determine the type of fuel line to use, such as the vehicle's make and model, performance requirements, and installation complexity, the budget is a crucial determinant. For those seeking an affordable option, Nylon Tubing emerges as a more cost-effective choice compared to rubber fuel hoses.
Nylon Tubing offers a budget-friendly alternative to rubber fuel hoses, which have traditionally been a popular choice for fuel lines due to their ease of installation and availability. Rubber fuel hoses are typically made from materials like nitrile (NBR) or EPDM (ethylene propylene diene monomer), designed to safely transport gasoline and other fuel types. However, they come with certain drawbacks, including their propensity to degrade as soon as they come into contact with fuel and their susceptibility to cuts, nicks, and abrasions.
On the other hand, Nylon Tubing provides a more durable and cost-effective solution. While it may not be suitable for the entire fuel system, it can be an excellent option for fuel line repairs on a budget. Nylon is known for its abrasion resistance and protective qualities, making it a more robust choice than plain rubber fuel hoses. Additionally, Nylon Tubing can be found in braided forms, offering enhanced strength and durability. This added layer of nylon also contributes to its flexibility, making it a versatile option for custom routing in tight or complex spaces.
When considering fuel line repairs, it's essential to prioritize safety and functionality. Nylon Tubing achieves this by providing a more durable and cost-effective solution than rubber fuel hoses. However, it's important to note that metal is considered the best material for fuel lines, offering superior durability and performance, albeit at a higher cost and with increased fabrication complexity. Nevertheless, for those seeking a balance between budget and quality, Nylon Tubing presents a compelling option, demonstrating that fuel line repairs can be achieved without compromising one's finances.
Regarding the size of the tubing, it depends on several factors, including the vehicle's make and model, the fuel pump, and the specific application. Common sizes for fuel lines include 4AN, 6AN, 8AN, and 10AN, catering to diverse fuel delivery systems. Additionally, the tubing itself can come in various dimensions, such as 8mm and 10mm for aluminum tubing, while hose sizes can vary from 6mm to 19mm internal diameters. It is always recommended to consult a professional or refer to vehicle-specific guidelines to ensure the appropriate tubing size is selected for the fuel line repairs.
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Fuel pump proximity: The pump should be close to the tank and below the outlet
When it comes to fuel lines, there are various factors to consider to ensure optimal engine performance. One crucial consideration is fuel pump placement in relation to the fuel tank and outlet. Here's an in-depth guide on why fuel pump proximity is essential and how to achieve the most effective setup.
Fuel pump proximity is critical for several reasons. Firstly, the primary purpose of this placement is to ensure efficient fuel delivery to the engine. By positioning the pump close to the tank and below the outlet, gravity assists in feeding fuel to the pump, a principle known as gravity feed. This setup is particularly important when using an external fuel pump, as these pumps are designed to push fuel rather than pull it upwards against gravity. A pump located too far away or above the outlet will struggle to draw fuel, leading to potential starvation and inadequate engine performance.
Additionally, the proximity of the pump to the tank and outlet can impact the overall efficiency of the fuel system. A closely positioned pump reduces the distance fuel has to travel, minimizing the chances of fuel starvation during acceleration or when fuel levels are low. This setup also helps maintain consistent fuel pressure, ensuring the engine receives a steady supply of fuel for smooth operation.
To achieve the ideal fuel pump proximity, it is recommended to keep the pump as close to the tank as possible and below the outlet. This placement ensures that gravity assists in fuel delivery rather than working against it. While a pump located slightly above the outlet may function, it is not optimal and can lead to potential issues, especially with external fuel pumps.
In some cases, the fuel pump may need to be mounted outside the tank, such as when using an aftermarket or external pump. In these situations, it is crucial to follow the manufacturer's guidelines for pump placement and fuel line sizing. Aftermarket pumps typically specify the required fuel line sizes, ensuring optimal performance and compatibility. Proper pump placement and fuel line sizing are critical to avoid issues such as fuel starvation or inadequate fuel delivery, which can negatively affect engine performance and, in extreme cases, cause engine damage.
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Fuel type: When using E85, alcohol, methanol, etc., use a bigger fuel line
When it comes to choosing the right fuel line size, it's important to consider the type of fuel you'll be using. If you're using fuels like E85, alcohol, or methanol, it's recommended to go up to the next bigger size of the fuel line. These alternative fuels have higher stoichiometric requirements, with E85, for example, needing around 30-35% more fuel than gasoline to achieve the same conditions. This means that your engine will require a larger fuel line to ensure an adequate supply.
Additionally, these types of fuel are highly corrosive and can wreak havoc on fuel lines and cells that are not designed to handle them. The corrosive nature of these fuels can cause deterioration and damage to your fuel system, so it's crucial to select a fuel line that is specifically rated for alcohol, methanol, or ethanol. By choosing a compatible fuel line, you can prevent issues such as rubber degradation and the release of small chunks that could clog fuel filters or injectors.
One option that works well with E85, ethanol, and methanol is PTFE (Teflon) fuel lines. PTFE lines are excellent for corrosive fuels as they are resistant to temperature and pressure effects, making them a durable choice. However, they can be more challenging to assemble and tend to be more expensive. Another option specifically for ethanol and methanol is the Fragola Premium Black Nylon Race Hose, which has a rubber inner hose reinforced with stainless steel and a durable black nylon outer braid.
When switching to alternative fuels like E85, alcohol, or methanol, it's important to consider not just the fuel line but also the compatibility of your fuel pump and injectors. These fuels often require larger injectors and a more powerful fuel pump to accommodate their higher fuel demands. Therefore, it's crucial to assess your entire fuel system to ensure optimal performance and prevent potential issues down the line.
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Hose fitting: JIC/AN fittings are common and sized by thread and hose size
JIC/AN fittings are the most common type of hose fittings for fuel lines. They are sized by a combination of thread size and hose size. JIC fittings are manufactured following SAE J514 standards and are commonly referred to as 37-degree flare fittings due to their 37-degree flare on the seating surface. They are suitable for a wide range of applications, including fuel oil systems. The fittings are available in various sizes, including 1/4", 3/8", 1/2", and 1" body sizes, with corresponding thread sizes.
When selecting a fuel line hose, it is important to consider the specific application and vehicle system. The hose should be easy to cut to length and is typically available in various internal diameters, such as 6mm, 8mm, 10mm, 12mm, 15mm, and 19mm. The hose can be secured with hose clips or swaged on and is intended for low-pressure or high-pressure applications.
There are several options for the hose material, including plain rubber or rubber with a stainless-steel over-braid for added protection. Another option is a Teflon/PTFE-lined hose, which can be used inside and outside the car as it prevents the escape of fuel vapour. This type of hose has a small outside diameter in relation to the bore size, making it suitable for tight installations.
In addition to JIC/AN fittings, there are other types of fittings available, such as BSP, ORFS, and NPT. BSP, or British Standard Pipe, has two popular thread forms: BSPP (British Standard Pipe Parallel) and BSPT (British Standard Pipe Tapered). ORFS fittings are becoming popular internationally due to their high-level sealing and good vibration resistance. NPT, or National Pipe Thread, is another standard type of thread used in plumbing and piping applications.
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Hose material: PTFE Lined Hose is the best soft hose, but requires special fittings
When considering what size tubing to use for a fuel line, it is important to remember that fuel pumps are sized to feed your system with enough fuel to optimise engine performance. However, the type of tubing material is also critical.
PTFE-lined hoses are an excellent option for fuel lines. They can be used both inside and outside the car because the liner prevents the escape of fuel vapour, eliminating the stale fuel smell inside the car. PTFE hoses are also ideal for long lengths because they have very little internal friction. They also have a small outside diameter in relation to the bore size, making them a good choice for tight installations.
PTFE hoses are available in dash 6 (-6) or dash 8 (-8) sizes, which relate the hose bore to the thread of the fitting. The fittings clamp to the hose with a compression olive, creating a very strong connection. PTFE hoses require PTFE hose end fittings, and the alloy fittings are available in red, blue, or black, while steel fittings have a plated finish.
Other options for fuel lines include zinc-plated steel tubing, which resists common types of corrosion and has a double-wall construction that provides strength and durability. Steel hardline is another common type of tubing used in most automotive systems. Annealed aluminium tubing is also popular as it is easily hand-formed, easy to cut and flare, and can be polished to a high sheen. However, aluminium is challenging to get perfectly straight, especially when purchased in rolls. It is important to note that aluminium tubing should never be used for pressurised brake lines.
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Frequently asked questions
The size of the tubing depends on the type of vehicle and its specific application. Common fuel hose sizes include 6mm, 8mm, 10mm, 12mm, 15mm, and 19mm internal diameters.
There are various types of fuel lines, including Fuel Injection Hose, Marine Fuel Hose, Farm Fuel Hose, Diesel Fuel Hose, and Fuel Transfer Hose.
Fuel lines can be made of different materials such as reinforced rubber, aluminium, zinc-plated steel, stainless steel, and Teflon/PTFE. The choice of material depends on factors such as ease of installation, durability, and cost.










































