New hard lines don't seem to fit--why?

[911SCRVA]

This is about the third project on my '81 SC and it's been a little challenging. Because of a leak, I ordered new rear oil lines and new hard oil lines. I'm happy to report that I replaced my rear oil lines without a hitch.




The hard lines, however, haven't been so easy. After realizing the ones I bought (930-207-045-03-OEM) didn't reach the external oil thermostat (they had squared thermostat ends and were a few inches too short), I bought oil lines with curved thermostat ends (930-107-017-01-OEM). So while I'm waiting for my new thermostat, I figured I'd install the hard lines today and attach them to the front oil lines. Everything looks ready for the thermostat...




Lo and behold, the hard lines appear too long to attach to the front oil lines.






Am I wrong in thinking something's not quite right? There is some flex to the hard oil lines, but I don't want to force them to mate with the hoses and bend the lines in the process. Are the front oil lines (hoses) too long? Is that even possible?

I'd appreciate any insights you can provide to get me back in this car. The new thermostat arrives this Thursday and I was hoping to drive it this upcoming weekend. That's not looking feasible to me.

Thanks in advance for your help.

[dg567]

Loosen up the cooler so you have some play up there. Leave everything loose and attach the thermostat when it comes in. After its all assembled start tightening down your fittings and cooler. These cars are old and hand built, nothing is going to fit perfectly out of the box.

[werke1]

I’d also get new cooler hoses up front, they get hard and leaky over time too

Just did this job and as Daniel said get everything in loose first and the parts will align themselves at the end.

[911SCRVA]

I'll give it a shot. Thank you.

Originally Posted by dg567

Loosen up the cooler so you have some play up there. Leave everything loose and attach the thermostat when it comes in. After its all assembled start tightening down your fittings and cooler. These cars are old and hand built, nothing is going to fit perfectly out of the box.

[911SCRVA]

I've looked and can't find front oil lines on Pelican. I'll call them tomorrow. Thanks.

Originally Posted by werke1

I’d also get new cooler hoses up front, they get hard and leaky over time too

Just did this job and as Daniel said get everything in loose first and the parts will align themselves at the end.

[dg567]

https://www.pelicanparts.com/More_Info/PELGRLINESET.htm?pn=PEL-GR-LINESET&SVSVSI=0828&DID=46368

[David Inc.]

Replacing my trombone with the radiator was one of the hardest jobs I ever did on my SC. Much like yours I didn't have enough room between the hard lines and the soft lines from the cooler. There simply wasn't room in the wheel well for the way the hard lines were bent so I had to add more curvature to them to take up more space at the top of the wheel well to take out some of that extra length.

I'm mad just remembering it.

[911SCRVA]

Thanks for the response, David. How did you add curvature? I'm afraid to ask.

Originally Posted by David Inc.

Replacing my trombone with the radiator was one of the hardest jobs I ever did on my SC. Much like yours I didn't have enough room between the hard lines and the soft lines from the cooler. There simply wasn't room in the wheel well for the way the hard lines were bent so I had to add more curvature to them to take up more space at the top of the wheel well to take out some of that extra length.

I'm mad just remembering it.

[David Inc.]

Originally Posted by 911SCRVA

Thanks for the response, David. How did you add curvature? I'm afraid to ask.

Partially dropping the lines, bending them, putting them back in, swearing, dropping them, bending them, putting them back in, swearing, dropping them....

If I were to do it again I might try to borrow a tubing bender from someone. Trying to do that without proper tooling only made it harder.

[911SCRVA]

Hahaha. Sounds like we're having similar experiences. At least the swearing part. Perhaps the bending part soon too.

Originally Posted by David Inc.

Partially dropping the lines, bending them, putting them back in, swearing, dropping them, bending them, putting them back in, swearing, dropping them....

If I were to do it again I might try to borrow a tubing bender from someone. Trying to do that without proper tooling only made it harder.

[Lz7w]

my experience is similar to others on this thread: getting the flexible lines in the front fender to fit takes a lot of work! what worked for me was to loosely install the cooler, install the cooler end of each flexible line, heat each flexible line with a heat gun to make it more flexible, then line up and thread the fitting onto the hard line. the flexible lines end up with pretty significant bends in them...

I didn't touch/bend the hard lines though.

[911SCRVA]

Have you had any issues with the soft lines since applying heat? Did it have any apparent effect on the braiding? Also, what temp setting did you use and how close to the lines did you get? I don't have any experience with a heat gun.

Originally Posted by Lz7w

my experience is similar to others on this thread: getting the flexible lines in the front fender to fit takes a lot of work! what worked for me was to loosely install the cooler, install the cooler end of each flexible line, heat each flexible line with a heat gun to make it more flexible, then line up and thread the fitting onto the hard line. the flexible lines end up with pretty significant bends in them...

I didn't touch/bend the hard lines though.

[stevie 77 930]

Get some new lines as your old lines have formed hard and are not very pliable any longer.
Be sure to get a pair of cloth braided Cohline as they are much more flexible than the all rubber lines

[7783911]

i too used the cohlines and attached to the cooler first, mounted the cooler loosely and then snug everything up...no problems getting a good fit

[rokemester]

Oh man this thread brings up some memories. Glad I’m not the only one to struggle with the front lines. Actually the entire process of line replacement was a royal pain in the arse! Make sure the new flexible lines are the correct size. One is shorter. Ask me how I know.

[mepstein]

You could always have the correct size soft lines made to fit.

[dtwa]

I have never done this job so I have no advice to offer. Your pics don’t show a thermostat. Without the thermostat in place and connected, are you sure the hard lines are correctly located?


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[rokemester]

Eventually got there. Note shorter line.

[pkabush]

I’m not sure I’d use Teflon pipe dope on the threads. They’re not tapered plumbing threads. So, not needed. Nor is Teflon tape. Probably not a issue but, some remnants will make it through the oil system/motor

[7783911]

an anti-seize (copper) might be a better choice in the long run? but heck..way to go getting it done!