Sylvie Willis
Fuel lines are graded according to their fire resistance and permeability, with A1 offering the highest fire resistance and lowest permeability, and B2 offering the lowest fire resistance and highest permeability. When sealing fuel lines, it is important to ensure that the sealant is compatible with the type of fuel (diesel or gasoline) and the material of the fuel line, such as plastic or rubber. Various sealants are available, including Teflon tape, liquid or paste thread sealants, and fuel-resistant synthetic rubber sealants. Seal-All, a multipurpose adhesive, can also be used to repair fuel leaks and seal fuel lines, as can JB Weld, a petroleum-resistant adhesive.
| Characteristics | Values |
|---|---|
| Type | Multipurpose adhesive |
| Usage | Used to seal, bond, insulate, waterproof, and stick to a wide variety of materials |
| Application | Does not require mixing or heating |
| Resistance | Resists water, gasoline, oil, and most solvents |
| Temperature | Does not become brittle in cold weather |
| Size | Available in 30ml and 60ml tubes |
| Application Process | Use the pointer cap to break the seal on the tube |
| Application Precaution | Do not squeeze the tube to force the seal open as this will allow too much air inside, and dry out the product |
| Surface Preparation | Apply to a clean, dry surface as wet Seal-All can damage the material |
| Cure Time | Ranges from 2-6 hours depending on the thickness of the layer |
| Post-Application | Put a thin coat of petroleum jelly on the threads of the cap before replacing it |
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What You'll Learn
Fuel line grades and their fire resistance
Fuel lines are graded based on their fire resistance and permeability, with A1-grade fuel lines offering the highest fire resistance and the least permeability. The four grades of fuel lines are A1, A2, B1, and B2. A1-grade fuel hose is the best choice for fire resistance and should be used below deck on the high-pressure side (after the pump). A2-grade fuel lines have lower fire resistance than A1, while B-type fuel hoses are more permeable and used for less volatile fuels like diesel. Within the B-type fuel hoses, B1 has higher fire resistance than B2. If in doubt, A1-grade fuel hose is recommended as it works everywhere and offers the highest safety.
When choosing a fuel line, it is important to consider the location of the fuel line run, whether above or below deck. Above deck means in the open, such as an outboard engine connected to an above-deck tank. The type of fuel also plays a role in the selection of the fuel hose, as some fuels may not be suitable for certain materials. For example, rubber fuel lines may not be compatible with certain fuels or chemicals, whereas metal fuel lines are generally compatible with all types of fuel.
Metal fuel lines, made from materials such as steel or aluminium, are typically more durable and expensive than rubber or braided fuel lines. They are resistant to wear and tear and are not prone to cracking or deterioration. On the other hand, rubber fuel lines can become hard and brittle over time, while braided fuel lines may be prone to leaks if the braid is damaged. Braided fuel lines are typically made from a metal or synthetic fibre braid wrapped around a rubber or elastomeric core. PTFE-lined fuel lines are known for their durability, flexibility, and resistance to wear, heat, and chemical damage.
To ensure safety and prevent fires, it is crucial to properly seal fuel fittings and fuel lines. Liquid or paste-type thread sealants are recommended for sensitive components, and the choice of sealant depends on its chemical resistance to the type of fuel or oil in the line. For gasoline, gasoline-resistant Aviation Form-a-gasket Number 3 is commonly used. Additionally, the use of two hose clamps at each connection point of the fuel line over the hose barb is advised to ensure even sealing tension.
Overall, understanding the fire-resistance ratings of different fuel line grades is essential for making informed choices and maintaining safety.
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Using sealants to prevent leaks
Teflon Tape:
Teflon tape, also known as polytetrafluoroethylene (PTFE) tape, is a thin, flexible tape that is wrapped around the male threads of a fuel line connection. It creates a seal by filling in the gaps and preventing leaks. It is important to wrap the tape in the correct direction, starting at the base and overlapping each layer by about half. While Teflon tape is a common and easy-to-use option, it may not be suitable for all types of fuel lines, and it is important to ensure that it does not interfere with sensitive components.
Pipe Thread Compound:
Pipe thread compound, also known as pipe dope, is a paste-like sealant that is applied to the threads of fuel line connections. It fills in any gaps and creates a tight seal to prevent leaks. When using pipe thread compound, it is important to apply a generous amount, starting at the base of the male threads and working your way outward. This type of sealant is effective in preventing leaks, but it may not be suitable for all thread types, and proper cleaning is essential before application.
Anaerobic Sealants:
Anaerobic sealants are liquid sealants that cure in the absence of air. They form a strong bond between the threads of fuel line connections. These sealants are often used in fuel sender type applications and are known for their medium solvent resistance. When using anaerobic sealants, it is crucial to follow the manufacturer's instructions and ensure proper ventilation during application.
Fuel-Resistant Silicone:
In some cases, a fuel-resistant silicone sealant may be suitable for sealing plastic fuel lines. This type of sealant is designed to be resistant to gasoline and other fuels, making it a good option for fuel system repairs. However, it is important to choose a silicone sealant that is specifically designed for this purpose, as not all silicones are fuel-resistant.
Epoxy and Super Glue:
For plastic fuel tanks, some people have found success using epoxy or super glue. Epoxy kits designed specifically for plastics can be used to seal leaks, and super glue is highly resistant to both gasoline and ethanol. However, it is important to clean the plastic surface thoroughly before applying these sealants and to follow the manufacturer's instructions.
Welding and Soldering:
In some cases, welding or soldering the plastic fuel line may be an option. This involves melting the plastic and using a soldering iron to create a seamless joint. While this method can be effective, it requires practice and proper ventilation to ensure safety.
It is important to note that while sealants can be a temporary solution to prevent leaks, they may not always be a permanent fix. For more severe leaks or faulty fittings, it may be necessary to replace the fuel line or consult a professional for a more durable solution. Additionally, when working with any type of sealant or adhesive, proper ventilation and safety precautions are crucial to avoid inhalation of fumes.
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Hose clamps and fittings
Hose clamps are vital to creating and maintaining an even sealing pressure in your fuel line and help prevent issues within your sealing system. When selecting a fuel hose type, it is important to first assess where the fuel line will be located. Above deck means in the open (such as an outboard engine connected to an above deck tank). There are four grades of fuel line: A1, A2, B1, and B2. A1 fuel hose offers the highest fire resistance and the least amount of permeability, so it is the best choice.
When making connections from a threaded port to a hose barb connection, ABYC guidelines recommend using two hose clamps made from marine-grade stainless steel at each connection point of the fuel line over the hose barb. The clamps should have even sealing tension. To plumb a fuel hose line, you must ensure the thread type is correct. If it is NPT or NPTF, use a male hose barb fitting. Brass or stainless steel is typically used for these components.
Liquid or paste-type thread sealants are better for sensitive components downstream. For gasoline, regular gasoline-resistant Aviation Form-a-gasket Number 3 is a good option. Seal-All is another multipurpose adhesive that can be used to seal fuel leaks. It can be used on a wide variety of materials, including most plastics and rubbers.
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Fuel tank repairs
One method to repair a plastic fuel tank is to use a special two-component epoxy glue. However, this approach has limitations, as the epoxy glue is rigid and can crack over time, leading to further fuel leaks. To address this, you can fill the crack with a small piece of HDPE plastic using a soldering iron set between 250-300 degrees Celsius. This ensures that the repair material behaves the same as the original tank material during temperature changes.
Another approach is to use a product like Honda Bond, a silicone-based adhesive that has proven effective in repairing plastic fuel tanks. Additionally, fibre glass repair kits have been recommended for cleaning and repairing plastic fuel tanks, similar to how you would repair a vehicle fender.
When repairing fuel lines, it is crucial to ensure an airtight seal. You can use gasket sealant or fuel-resistant silicone to seal around the point where the fuel line enters the tank. For threaded connections, liquid or paste-type thread sealants are preferable as they are less likely to cause clogging. It is also important to select the appropriate thread sealant based on its chemical resistance to the type of fuel (diesel or gasoline) or oil running through the line.
To plumb a fuel hose line, you must determine the thread type. If it is NPT or NPTF, use a male hose barb fitting, preferably made of brass or stainless steel. For connections from a threaded port to a hose barb, ABYC guidelines recommend using two marine-grade stainless steel hose clamps at each connection point for added safety.
Remember, when in doubt or dealing with significant repairs, it is always best to consult a certified marine or automotive professional to ensure the safety of yourself and others.
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Fuel line replacements
There are four grades of fuel line: A1, A2, B1, and B2. A1 fuel hose is the best option for fire resistance and has the least permeability. B-type hoses are more permeable and used for less volatile fuels like diesel.
Before replacing a fuel line, it is important to depressurise the fuel system. This can be done by removing the fuel pump fuse from the fuse box, starting the engine, and running it until it stalls. It is also important to wear safety glasses when working with the fuel system, as the fuel is highly pressurised.
There are three main options for replacing fuel lines:
- Replace the entire line with a pre-bent line: This is the most expensive and labour-intensive option, but it returns the vehicle to like-new condition and prevents future leaks.
- Bend your own lines: This option requires investing in bending and flaring tools, as well as quick disconnect fittings.
- Nylon tubing: Nylon tubing can be used to replace an entire length of fuel line or just a section. This option is cost-effective and time-efficient, especially when pre-bent lines are not available.
When selecting a new fuel hose, it is important to first assess where the fuel line will be located, either above or below deck. Above deck means in the open, such as an outboard engine connected to an above-deck tank. It is also important to ensure that the new fuel hose is as long as or longer than the old one to prevent kinks in the hose, which can restrict fuel flow.
To install the new fuel hose, place new hose clamps around it and tighten them to secure the hose. It is recommended to use new hose clamps, as old clamps may not hold the hose tightly enough, leading to leaks.
After installing the new fuel hose, it is a good idea to test the vehicle by driving it around the block and monitoring the fuel level and engine light. If the engine light comes on, there may be an electrical issue within the fuel system, and a certified mechanic should be consulted.
For plastic fuel lines, it is important to be careful during removal as they can break easily. Additionally, when sealing fuel fittings and fuel lines, it is important to choose the appropriate thread sealant that is chemically resistant to the type of fuel or oil running through the line. Liquid or paste-type sealants are recommended to avoid clogging.
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Frequently asked questions
Seal-All is a multi-purpose adhesive that can be used to bond, seal, insulate, and waterproof a wide variety of materials. It is used by hobbyists and professionals alike to repair oil, water, and gas leaks.
Seal-All can be used on wood, steel, aluminum, copper, most plastics and rubber, porcelain, glass, vinyl, fiberglass, and leather, among many others.
Seal-All is available in two sizes, 30ml and 60ml, at Gregg Distributors. It can also be purchased at Walmart.
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