How To: Nylon fuel line without $$expensive$$ tool.

Aceshigh

Veteran Member
Lifetime Gold Member
Apr 9, 2001
26,757
Boondocks
Pretty ingenious method I found tonight while doing some research on Nylon fuel lines.
Budget fuel line option raiding the yards, and doing this saves some $$$LOOT!!!$$$
All new cars have this type of fuel line and fittings I've been told.

Saves you the $100 on the Dorman Nylon compression tool.
However, I'm not sure how it will work out with 90* fittings.

http://ls1tech.com/forums/15193388-post19.html

Here’s what you’ll need:
A roll of tubing (Dorman 800-072 is the 3/8”)

The appropriate fittings for your job

Some light lubricant (I used hydraulic jack oil)

The line clamp from a brake line flaring kit (don’t worry if you don’t have this, there’s an alternative)

A caulking gun

A single edge razor blade or tubing cutter that used for air line (gotta be something that won’t crush as it cuts)

To start, make a clean cut of the tubing. I used a single edge razor blade.
Next, insert the end of the tubing through the end of the caulk gun as shown.

Now, clamp the tubing in the flaring tool clamp using the hole in the clamp that corresponds with the size of your tubing. Leave only enough tubing sticking out to fit all the way on to the fitting (I've actually got a little too much sticking out in my pic). Clamp it tightly, but only hand tight. It won’t slip. You don’t need it as tight as is required when flaring brake lines. If you’ve done that job, you know what I’m talking about.

Now seat the clamp in the far end of the caulk gun as shown. Be mindful of the tubing past the clamp. Don’t let it get any pressure on it and get kinked.
Now add a little light lubricant to the fitting. Just enough to get it shiny, it doesn’t need to be dripping wet.

Great, now it’s time to assemble! Move the plunger forward in the gun until there’s just enough room for the fitting between the plunger and the tubing. Align the fitting with the end of the tubing and hold them in alignment with your fingers while you start to squeeze the handle of the caulk gun. Watch closely because it only takes 2-3 clicks to seat the fitting fully.

Take the clamp off of your tubing and you’re ready to move on to the next one!
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sbca96

Veteran Member
Oct 25, 2004
2,897
Santa Barbara, Ca
The only thing I would be concerned about is the aggressive grooves inside
the tubing holder making those marks on the outside of the plastic. Maybe
if the tool was modified to remove the grooves by drilling it out first? Also I
had read those soaking the tubing end in hot water for 20 seconds eases
the installation process. I dont recall a lubricant though.

Tom
 

John Wright

Veteran Member
Lifetime Gold Member
Aug 9, 2002
15,400
Rustburg, Va
sbca96 said:
The only thing I would be concerned about is the aggressive grooves inside
the tubing holder making those marks on the outside of the plastic. Maybe
if the tool was modified to remove the grooves by drilling it out first?
could pad the block/vice with a piece of innertube and it might help keep it from slipping through also.

I also agree with the hot water soak to soften the tubing.
 

cubs2008

Veteran Member
Jul 30, 2008
245
Chicago, IL
I would like to see the pressure test as well. Also, I have seen two ply type hose and what happens is the barb forces the inside ply apart from the outer one. I will admit, doint this job sucks!
 

Christian GM

Veteran Member
Jul 14, 2007
146
Italy
hi guys,
FYI also the Dorman tool (that I have and I use sometimes in my shop) leave the marking outside the tubing, as you say in post #2.
I think it isn't an issue.

bye
 

Aceshigh

Veteran Member
Lifetime Gold Member
Apr 9, 2001
26,757
Boondocks
This is unbeatable.....
You can plumb your entire system for under $100 with NEW OEM lines.
http://www.dormanproducts.com/catalog/OESolutions2006/327-342QuickDisconnect.pdf

You get packs of 5 fittings each for $12.99 or 2 for $6.99
I just spoke with Dorman via chat to confirm this is correct.
Any part #'s that end in ".5" like 800-082.5 = Quantity of 5
So Advanced is the best place to get all of these parts with the $20 off $50 coupons.

Example $12.99 > DORMAN 800-082.5 3/8 to 3/8 straight QTY = 5

4
 
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