Replacing rusty fuel lines. What to use? Fittings?

[rcx106]

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.

[rcx106]

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!