Plastic Fuel Lines, what to use? - Defender Source
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Old December 31st, 2015, 11:25 AM
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Plastic Fuel Lines, what to use?

I'm at the stage in my 300tdi build where I'm looking to start running fuel lines and I'm looking for a bit of advice what direction to go and where to source them.

The plan was to run hard plastic lines, Nylon I'm assuming, with barbs inserted and small sections of flexible pipe to the sender and lift pump.

The problem I'm having is sourcing the hard plastic fuel lines (in Ottawa). Are people running lines that can be heat formed like the stock lines? Or simply lines that can be gradually curved?

The only local source I've found is for FMSI nylon lines and supplier tells me they're gas and diesel rated, but I can't find any information about them being heat form-able.

Any info you guys can provide would be greatly appreciated, Brand, supplier etc.

Happy New Year!

Will
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  #2  
Old December 31st, 2015, 11:43 AM
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Hey Will, I have utilized rubber tube lines in a pinch (literally when an aluminum fuel line got pinched and started leaking). Have you considered utilizing rubber tubes? It seems like such a good option and very inexpensive too.
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Old December 31st, 2015, 11:51 AM
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Quote:
Originally Posted by chuckc4 View Post
Hey Will, I have utilized rubber tube lines in a pinch (literally when an aluminum fuel line got pinched and started leaking). Have you considered utilizing rubber tubes? It seems like such a good option and very inexpensive too.

I thought about it, but I was concerned about two things. First the diameter, not sure it will fit through some areas like between the bolt on cross member and rear tub.
Also I've heard you need to anchor them in many more places since they flex quite a bit more they are more likely to rub on things and wear.

Maybe these aren't real concerns and I'm open to whatever is a good solution.
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Old December 31st, 2015, 11:54 AM
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I ordered all my nylon fuel line from McMaster-Carr. I went all fancy and got clear nylon so I can see that there's diesel in the line...
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Old December 31st, 2015, 11:55 AM
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Originally Posted by o2batsea View Post
I ordered all my nylon fuel line from McMaster-Carr. I went all fancy and got clear nylon so I can see that there's diesel in the line...

Are you able to form it with heat to do slight bends?
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Old December 31st, 2015, 12:06 PM
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Quote:
Originally Posted by Wilboro View Post
Are you able to form it with heat to do slight bends?
Use a heat gun to soften the ends so you can push it onto the metal pipe stubs. You don't really need barbed fittings. Heat to make curves, yes. It has a very narrow heat range in that a little too much and it'll melt, too little and it won't take a bend.
McMaster-Carr
Item 8359K16 5/16 ID, or 8365K25 8MM ID
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Old December 31st, 2015, 12:10 PM
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Quote:
Originally Posted by o2batsea View Post
Use a heat gun to soften the ends so you can push it onto the metal pipe stubs. You don't really need barbed fittings. Heat to make curves, yes. It has a very narrow heat range in that a little too much and it'll melt, too little and it won't take a bend.
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Item 8359K16 5/16 ID, or 8365K25 8MM ID
That's great thanks! Did you use any sort of abrasion resistant sleeves anywhere over top?
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Old December 31st, 2015, 12:21 PM
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Quote:
Originally Posted by Wilboro View Post
That's great thanks! Did you use any sort of abrasion resistant sleeves anywhere over top?
No need that stuff is crazy tough
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  #9  
Old December 31st, 2015, 12:24 PM
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The stock lines are 3/8" nylon tubing. Any hose supplier. They are used for air brake lines on trucks. Very common and very cheap. Some front lines are 5/16", which is less common.

If you want to hot bend them, the safest way us to put the tubing in boiling water. You can do it with a heat gun, but you need to be careful. When it reaches the softening point, it gets very soft very fast.

Fuel Lines | Land Rover Modifications | Red90's Photos! | Red90.ca
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Old December 31st, 2015, 12:35 PM
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Would anyone have experience with Parker's Series 397 Super-Flex FL Barrier Fuel Line Hose: SUPER-FLEX FL Barrier Fuel Line Hose, Series 397 | Parker NA?
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  #11  
Old December 31st, 2015, 12:43 PM
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superflex seems overkill.
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Old December 31st, 2015, 01:11 PM
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Originally Posted by sonoronos View Post
superflex seems overkill.
Ok. I'll look for something else.
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Old December 31st, 2015, 02:51 PM
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I always use the generic rubber lines over the original plastic which I despise.
The plastic lines bend and bulge, buckle, flatten, and kink.
A kink can cause a split which lets air in and often fuel out of a plastic line.
The also get brittle and are effected by UV rays.

If you're going to use bio-fuels, then viton lined rubber lines are preferred.
With Rubber lines, you can join, clamp, and cut to the desired length.
You can also use metal barbed fittings sliding the rubber line over for a secure fit.
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Old December 31st, 2015, 03:00 PM
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Bundy-Flex copper lines come in different sizes, are NASA approved, can be bent around a 1"1/2 diameter pipe by hand without kinks, are fire resistant more so than plastic, are cheap and places like NAPA sbould carry them.
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Old December 31st, 2015, 03:18 PM
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Quote:
Originally Posted by rdavisinva View Post
If you're going to use bio-fuels, then viton lined rubber lines are preferred.
With Rubber lines, you can join, clamp, and cut to the desired length.
You can also use metal barbed fittings sliding the rubber line over for a secure fit.
Did anybody ever put together a Viton conversion parts list that had the right-sized hose and all of the little clamps that you'd need?
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Old January 1st, 2016, 10:11 AM
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Hmm sounds like some other options that might be worth considering... For those who have used rubber lines did you have to anchor them in more locations to prevent vibration and rubbing?

My original lines are nominally 10mm OD and 8mm OD for the return line. Is there any reason I can't run 10mm/ 3/8 for the return line as well?
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Old January 1st, 2016, 10:29 AM
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Is there any reason I can't run 10mm/ 3/8 for the return line as well?
Not at all. That is what I have done as fittings are much more common in 3/8".
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Old January 1st, 2016, 10:30 AM
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Not at all. That is what I have done as fittings are much more common in 3/8".

Ok great.

The fittings you used were they just off the shelf airline fittings?
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Old January 1st, 2016, 10:36 AM
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You may be able to utilize cushion clamps to anchor the fuel line
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Old January 1st, 2016, 10:38 AM
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Originally Posted by Wilboro View Post
Ok great.

The fittings you used were they just off the shelf airline fittings?
If you look at my link, I provided info in the comments of the pictures. You need some adapters to get from the strange and mysterious fittings LR uses to normal ones. From there, I have used normal 3/8" compression fittings with tube inserts from Home Depot.

One thing you need to watch if going this route is some of the steel tubing is 5/16" and some is 8mm. 5/16" is smaller and a 5/16" compression fitting will not fit an 8mm tube. 8mm fittings are not easy to find. I was able to successfully drill out the 5/16" compression fittings to 8mm. Your mileage may vary.

Alternatively, you can do it the way it is done at the factory and heat fit the nylon over the steel tubes. I just did not like that method for future field repairs.

PS: Note my truck has a custom dual tank setup. Normal stock single tank is a lot simpler.
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