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Join Date: Jun 2009
Location: New England
Posts: 850
How to Make Fuel Injection Lines

I decided to make my own plastic fuel lines; after soliciting the opinions of fellow Pelicans and doing lots of research. I also took the advice of Dan Jacobs at Hairy Dog Garage who told me he thought the plastic factory lines were perfectly fine for street use.

I used Alan Lindquist’s woodblock method outlined in this thread:

Easy Fuel Line Repair

Alan’s right, this method is ‘quick and easy.’ Very easy! Dawdling along, I made my oak jig and fabricated all the fuel injection lines in an afternoon.

Not knowing the Pelican protocol concerning adding to someone else’s thread, I thought I’d just share a few photos.


Cut the woodblock in half, lock the two halves in a drill press vise, and then drill the holes.




Trim fuel line flush.




Heat the fitting gently.


Use a soft hammer or block of wood to tap the heated fitting into the fuel line.


With the fuel line flush with the block, I found it easiest to drive the fitting halfway and then raise it slightly above the block to drive the fitting home.


Finished

Old 02-24-2019, 03:32 PM
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Location: New York.NY
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What was the size drill bit you use to make holes ? I see you have three different sizes
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Old 02-25-2019, 09:16 PM
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Like you your tool for pressing the CIS lines onto the fitting. Be sure you get nylon tubing with the correct wall thicknesses.

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Old 02-26-2019, 12:15 AM
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Angel, I drilled 8mm, 6mm, & 5mm holes. The 8mm hole accommodates the 6mm ID lines between the fuel distributor and the tank fitting, WUR, etc. The 6mm hole accommodates the 4mm ID fuel injector lines. The 5mm hole is for the 3mm ID line between the center fitting on the fuel distributor and the control pressure regulator.

It’s not a huge problem, but the tubing tends to slide down into the block when you hammer in the heated fitting. Make the block as long as possible, drill the holes slightly under-size; and clamp both ends of the jig to get the best grip. Making the block out of hard rubber rather than hard oak might be better. Again, not a big deal. You just need to fiddle with it.

Harry, thanks for adding those links! It's sometimes hard to find stuff, even with the search function. It would be great if there were some way to organize forum topics in 'chapters' -- brakes, fuel, wheels, etc.

Good point regarding tubing wall thickness! The plastic tubing I used iis Cohline and rated for ethanol fuels. It's the same tubing used in pre-made lines, so I'm pretty sure it has the right wall thickness.

I got the tubing and fittings from Belmetric in Massachusetts and they were just great to work with!

Robert

Old 02-26-2019, 07:30 AM
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