Finally Got the Second Fuel Line In

[Steam Driver]

I FINALLY got the second, return to tank, Porsche fuel line pulled through the tunnel this afternoon. As you may recall I've had a lot of trouble with that second line after the first (pressure) line went through so easily. This one kept catching on something about 15 - 18 inches ahead of the rear bulkhead and in an inaccessible place, and that was just in trying to pull the original one out! I finally gave up on using the old line to pull the new fish tape through from the rear, cut the front end off of it, and pulled it out from the rear, at the same time pulling in a length of 17 ga. AL electric fence wire to use as the new pull wire. After that I looked in the tunnel with a Rigid "See Snake" which gives a pretty good image, but for the life of me I couldn't see what it was snagging on.

I tried several times over the last week or so to pull the new line through, but always with the same result; a solid snag, always in that same place. It was beginning to look like the return line was going to be outside the tunnel; I had already picked out a route behind the driver's side rocker panel next to the A/C line that's already there. But I wanted to make one last all-out effort first. This technique may be overkill, but it worked and may be useful to someone else.

Thinking it over I decided that at least one reason it was snagging was that the pull wire was pulling off center, with the fuel line hanging down below it (gravity being what it is) ready to catch on anything. It also wasn't very streamlined. So I began thinking along the line of streamlining and came up with using a wire nut to taper it down (the red size is a good fit over the tapered end of the rear fitting; if you use the "winged" kind you need to grind those off), and so the fish wire would pull more in the center I drilled a hole in the center of the end of the wire nut to put the pull wire through.

I also was having some issues with the electrical tape I used to connect the pull wire to the fuel line, so I thought covering it in something smoother a good idea. Enter 3/4-inch shrink tubing (1/2-inch is just a trifle too small). I cut about a five inch length of that and pushed it and the wire nut up the wire before connecting the wire to the fuel line. I did the latter by bending the soft AL wire around the fitting a couple of times then running it up the line several inches by spiraling it around the line. I then taped over all that with electrical tape putting the wire nut on with the pull wire centered at the same time. Then I brought the shrink tubing down over it and shrunk (shrank?) it. I had to finish off the small end with a bit of electrical tape.

Then for good measure I lubed it a little with Dow 111 silicone grease. Result? It went through. It still hung up a little in the places I had had trouble with before, bit thanks to the tapering, the lube or both, we were able to pull it through. Overkill measures? Maybe. But it's in there and back to stock.

[steely]

You have my sincere congratulations for your perseverance (bull-headedness), and success.
I too had similar problems but my snag wasn't as bad as yours (I have an 87), but it wasn't easy either. I like to think I built a lot of character during those days earlier this sumer.

I would wind up using what was later described by fellow Pelican "Bob Kontak" as Sex Lube. I used water based goo from the local drug store chain and out of frustration gave a pretty healthy pull while laying under the car.

I don't think anything was cut or perforated. If anybody has a bore sight cam, a pic of the tunnel within the tunnel would be a big help to others in the future. I no longer smell gas in the garage!!!

I also agree with you that gravity and streamlining play a big role. I used stick to try to guide the line over the first one I pulled. My snags were against the metal straps or keepers just outside of the inside tunnel.

Double check the lay of the line especially in the vicinity of the pedal cluster, because the throttle linkage may touch the newly installed line, so you may have to adjust that.

Also, use the lube on the grommets - major help.
A tip of the hat to you!!!

[Steam Driver]

Another thing I tried during this ordeal, with partial success (it worked on the first line, the pressure line) was that before I pulled the line out (from the front, natch) I put a length of 1/2-inch vinyl tubing (hardware store) over the fitting at the rear end of the line. This is a tight fit but not secure enough to use as a pull line so I also ran a length of string trimmer line through the middle of it and taped that along side the old fuel line.

It pulled out easily. Then I reinstalled all the above on the rear of the new line and it pulled through "slicker than snot on a doorknob." (As they say.) The idea of the 1/2-inch tubing was to keep the path open for the new line. Worked great.

But when I tried to repeat that on the return line I couldn't pull it through to get it out. It kept hanging up solidly on something about 15 - 18 inches into the tunnel. Later I inspected that area with the "See-Snake" and found nothing (obvious) there for it to snag on. Very odd, but it's done now.

[911SauCy]

I'm in process of having a Aeroquip lines made, which will be outside the tunnel.

God Bless your soul making this happen.