Making Your Own Fuel Lines
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Fleet Owner
Joined: Aug 2001
Posts: 29,941
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From: Drummonds, TN USA
Making Your Own Fuel Lines
How To: Make a stock line, using the original end fittings
Not long ago, I ran into a wierd situation on a Mustang that came together out of an '86 that was rusted to bits, a newer body ('89, I think it was) and a 1990 and onward harness.
We had no fuel pressure on light-off after going the whole nine on the project in less than 6 weeks. Reason- No pump in the tank...
The new body had been used as a street/strip project, but it stalled. There had been plans to lay in a much higher capacity fuel pump back at the tank, and I suppose before "Our Friend" bought the chassis, the pump had been scavenged out of it.
The lines under the car had been modified, and had similar fittings to both Ford Diesel and Gas fired trucks (O-ringed cups, with horse-shoe clips to retain them, on plastic line).
"Oh My GEE..." A dealer item, unless you can find an undamaged set at a salvage yard...
Think again!
DIESEL truck supply houses (as in BIG RIG) have plastic line that shrinks to fit with a heat gun, it is teflon lined tubing that exceeds the original Ford fuel line pressure and fuel resistance specs, and can be molded to any shape. It is used to repair/rebuild air brake lines...
If you carefully cut the bell fittings out of the ends of the old line(s), and work them with a heat gun (You can't use a bic lighter for this) you'll have fuel-proof lines that can withstand as much as 150 PSI, a lot more than any fuel pump puts out that I ever heard of.
I know of a car in my area that has had a set of these lines on it for at least six years now, and it still doesn't leak at all.
In our case - we had to find another line with the correct size coupler to adapt a pump output that was larger than stock. (Take note, HI-PERF people) - With a pump like that, it also helps to go one size up on the line itself, and get bell couplings with larger nipples in order to increase total fuel flow volume.
~Greywolf sendz...
Not long ago, I ran into a wierd situation on a Mustang that came together out of an '86 that was rusted to bits, a newer body ('89, I think it was) and a 1990 and onward harness.
We had no fuel pressure on light-off after going the whole nine on the project in less than 6 weeks. Reason- No pump in the tank...
The new body had been used as a street/strip project, but it stalled. There had been plans to lay in a much higher capacity fuel pump back at the tank, and I suppose before "Our Friend" bought the chassis, the pump had been scavenged out of it.
The lines under the car had been modified, and had similar fittings to both Ford Diesel and Gas fired trucks (O-ringed cups, with horse-shoe clips to retain them, on plastic line).
"Oh My GEE..." A dealer item, unless you can find an undamaged set at a salvage yard...
Think again!
DIESEL truck supply houses (as in BIG RIG) have plastic line that shrinks to fit with a heat gun, it is teflon lined tubing that exceeds the original Ford fuel line pressure and fuel resistance specs, and can be molded to any shape. It is used to repair/rebuild air brake lines...
If you carefully cut the bell fittings out of the ends of the old line(s), and work them with a heat gun (You can't use a bic lighter for this) you'll have fuel-proof lines that can withstand as much as 150 PSI, a lot more than any fuel pump puts out that I ever heard of.
I know of a car in my area that has had a set of these lines on it for at least six years now, and it still doesn't leak at all.
In our case - we had to find another line with the correct size coupler to adapt a pump output that was larger than stock. (Take note, HI-PERF people) - With a pump like that, it also helps to go one size up on the line itself, and get bell couplings with larger nipples in order to increase total fuel flow volume.
~Greywolf sendz...
Last edited by Greywolf; Feb 13, 2005 at 06:05 PM.
Thread Starter
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Fleet Owner
Joined: Aug 2001
Posts: 29,941
Likes: 46
From: Drummonds, TN USA
Unless it was built into the line itself - I have no idea. Except that you could get aftermarket dress-up stuff to put over it, which to me seems a bit silly. Lines run in safe areas where they would be protected should never be subjected to road grit, or "stuff thrown up by tires".
I never thought about armor plating them, but niether did FORD.
~ Wolf
PS: Good to hear from you
I never thought about armor plating them, but niether did FORD.
~ Wolf
PS: Good to hear from you
Posting Legend
Joined: Sep 2001
Posts: 30,255
Likes: 37
I asked because the lines in the engine compartment of my vehicles have a SS braid covering. 
I have used regular rubber EFI hose and clamps to replace lines before. I buy 10' at a time to keep a supply of that hose in stock.
-Long time no hear from you either!
I have used regular rubber EFI hose and clamps to replace lines before. I buy 10' at a time to keep a supply of that hose in stock.-Long time no hear from you either!
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