I am finally getting around to fixing/replacing/updating the fuel system on my 1984 Mustang. That has always been an area that I would update some day, but now to the point where the day needs to be this winter. The original factory lines need to be replaced as they were never designed for a dual exhaust V8, as my car was a 2.3L car from the factory. The metal lines run along the passenger side muffler, and terminate in the engine compartment in close proximity to the header collector on the driver's side. Not good at all. My car also has MM subframe connectors and torque arm, so lots of bits that make running factory lines difficult. I need a fuel line that can go from the fuel tank to the mechanical fuel pump located on the side of the engine block. I have charted out a route that takes the line across the front edge of the tank, over the driver's side axle, down the frame rail, and to the fuel pump with the least amount of bends and the furthest away from moving parts and heat sources.
Now the hard part, what to use?
- Factory bent replacement lines? Probably not due to the proximity to heat sources and difficulty in routing around aftermarket parts.
- Soft rubber, such as Earl's Vapor Guard? This looks like a decent option as it has low permeability and suitable for pump gas, which eats rubber hoses after a few seasons. Bad part is concerns over running soft hose under the car. I would need some road debris shielding.
- Push-Lock hose? Difficult to assemble the barbs on the hose, still a soft hose that is exposed to potential road debris, and some versions are not good for pump gas with ethanol and others leech gas odors/fumes.
- Braided nylon? Ok, better in terms of running under the car, but depending on the type, may only be good for 3-5 years before it needs to be replaced.
- Stainless steel braided? The classic AN style hose, but not suitable for pump gas unless it has a PTFE liner, meaning it needs special fittings to assemble. Permeation of fumes is also a concern. Cost to run decent stainless steel line from the tank to pump can cost well into the hundreds and still may not last long. Also stainless steel has electrostatic concerns as electricity can arc between the fuel and stainless steel, causing pinholes in the PTFE lining, which leads to leaks.
- Modern nylon fuel line? This is what OEM's use today and is impact resistant for under car use. It can be formulated with ETFE to resist electrostatic buildup and protect the nylon from being attacked by the pump gas. Bad thing is trying to find OEM spec nylon fuel line. Not like Ford will just sell a 20 foot roll of it. Aftermarket stuff is questionable for what the composition of the nylon is, so getting it wrong could be very bad.
- Stainless steel hard line? Tough to route, tough to bend, need to be flared to work, but suitable for under the car.
So, lots of options, none are good. I have posted over on Corral, but not happy with the results. Most are running EFI and solutions suggested are of questionable quality and safety. To make things worse, every option I research has one article saying to avoid it while the next article says it is the best solution. There must be something that can connect the tank to the pump, work with pump gas, won't crumble in a few years, and doesn't cost more than the car. I am not running the 24 hours of LeMans with the car.
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