Replacing rusty fuel lines. What to use? Fittings?
Discussion
The fuel lines on my 16V Vitara (Injection) are rusty. My car's having an overhaul so I'm looking at replacing them. The fuel tank has already been replaced as I found a tiny rust hole in it and this is a modified car so it's quite valuable to me.
There are three steel fuel pipes running along the chassis from the rear tank to the engine bay. One pipe uses high pressure screw fittings and has a bigger outer diameter than the other two. I imagine this is the main feed. The other two are thinner and use jubilee clips or spring clips (depends where) to join to 6mm ID flexible hose at each end. I guess one is a return line, and the other goes to the charcoal canister.
The rubber hoses on the main high pressure line are fine. It's just the steel pipe that's rusting. So I think I need to replace:
1. The steel pipes, in two thicknesses
2. The flexible 6mm hoses on the low pressure lines (easy)
I've replaced my brake pipes before and it was nice and easy. I used copper (90% copper to resist annealing), so I could shape the pipes. Could I also use copper on fuel lines? Is it the same technique to flare the ends?
I should be able to reuse the fittings on the high pressure line.
Is there any disadvantage to using flexible fuel hose instead of the steel hose? It would certainly be easier to fit.
There are three steel fuel pipes running along the chassis from the rear tank to the engine bay. One pipe uses high pressure screw fittings and has a bigger outer diameter than the other two. I imagine this is the main feed. The other two are thinner and use jubilee clips or spring clips (depends where) to join to 6mm ID flexible hose at each end. I guess one is a return line, and the other goes to the charcoal canister.
The rubber hoses on the main high pressure line are fine. It's just the steel pipe that's rusting. So I think I need to replace:
1. The steel pipes, in two thicknesses
2. The flexible 6mm hoses on the low pressure lines (easy)
I've replaced my brake pipes before and it was nice and easy. I used copper (90% copper to resist annealing), so I could shape the pipes. Could I also use copper on fuel lines? Is it the same technique to flare the ends?
I should be able to reuse the fittings on the high pressure line.
Is there any disadvantage to using flexible fuel hose instead of the steel hose? It would certainly be easier to fit.
Assuming you don't want to buy OEM replacements?
You'd get good advice on locostbuilders, as all kit builders have to go through this
copper heating pipe connected by lengths of rubber fuel hose is commonly used and can be flared, or you can braze a plumbing olive near the end to give the same effect.
Otherwise go for some decent braided hose like aeroquip and do the whole lot in one run, that's what I did but it's rather more expensive, fewer joins though.
You'd get good advice on locostbuilders, as all kit builders have to go through this
copper heating pipe connected by lengths of rubber fuel hose is commonly used and can be flared, or you can braze a plumbing olive near the end to give the same effect.
Otherwise go for some decent braided hose like aeroquip and do the whole lot in one run, that's what I did but it's rather more expensive, fewer joins though.
CrutyRammers said:
Assuming you don't want to buy OEM replacements?
You'd get good advice on locostbuilders, as all kit builders have to go through this
copper heating pipe connected by lengths of rubber fuel hose is commonly used and can be flared, or you can braze a plumbing olive near the end to give the same effect.
Otherwise go for some decent braided hose like aeroquip and do the whole lot in one run, that's what I did but it's rather more expensive, fewer joins though.
You'd get good advice on locostbuilders, as all kit builders have to go through this
copper heating pipe connected by lengths of rubber fuel hose is commonly used and can be flared, or you can braze a plumbing olive near the end to give the same effect.
Otherwise go for some decent braided hose like aeroquip and do the whole lot in one run, that's what I did but it's rather more expensive, fewer joins though.
TVR used copper for hard lines front to rear never seen or heard of one failing its just domestic 8mm copper tube sold on a roll you can solder the little olives on the end so you have a bead for the 8mm EFI hose to climb over without the worry of the hose blowing off under high pressure just use suitable fuel line clips i.e Mikalor etc rather than Jubilee clips 
No problem with copper, and yes just use a flaring or beading tool of sorts to create a lip to help retention.
Or some will compress an olive into the pipe, then remove the body of the compression fitting leaving the olive as a bead.
But depending on pressure, quality of hose and clamps, 99% of the time simply clamping will work just fine, or double clamp to be sure to be sure.
Or some will compress an olive into the pipe, then remove the body of the compression fitting leaving the olive as a bead.
But depending on pressure, quality of hose and clamps, 99% of the time simply clamping will work just fine, or double clamp to be sure to be sure.
It's all about the fuel pressure
The copper microbore pipes we use are ok for standard injection pressures with injection rubber hose as joiners so best not to exceed this pressure
With common rail systems running more and more pressure you'll want to check the copper tubes working pressure is good enough for your system
The copper microbore pipes we use are ok for standard injection pressures with injection rubber hose as joiners so best not to exceed this pressure
With common rail systems running more and more pressure you'll want to check the copper tubes working pressure is good enough for your system
PaulKemp said:
It's all about the fuel pressure
The copper microbore pipes we use are ok for standard injection pressures with injection rubber hose as joiners so best not to exceed this pressure
With common rail systems running more and more pressure you'll want to check the copper tubes working pressure is good enough for your system
I doubt any copper lines would ever be considered safe or usable for common rail stuff.The copper microbore pipes we use are ok for standard injection pressures with injection rubber hose as joiners so best not to exceed this pressure
With common rail systems running more and more pressure you'll want to check the copper tubes working pressure is good enough for your system
Even the factory steel lines will be substantial wall diameter, same as ld diesel lines.
Forget copper, I'll go with whatever the recommended solution is! I spoke to one supplier and they say alloy or stainless steel is normally used, but the latter needs a proper pipe bender.
I've noticed that the rubber hoses on the main feed have approx 1 inch external diameter, so yeah pressure could be an issue!
I've noticed that the rubber hoses on the main feed have approx 1 inch external diameter, so yeah pressure could be an issue!
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