Replacing D1 3.5 Fuel Lines? Ideas?

Hello again

So I was just getting the car finally together to go offroad tomorrow, after repairs this week from shearing a swivel ball off last week, and she decides to spring a leak!

The chassis fuel pipes were very rotten tbh and I have looked at them in disgust for ages. Yesterday one of them decided to go through.

Yesterday evening I got underneath, and within an hour had undone tank end, undone fuel rail end, removed filter and ripped out the remaining pipework.

I plan to replace with rubber or braided rubber hose, hopefully I will be able to get the appropriate fittings crimped on, assuming they are standard threads etc.

Before I go any further I thought I would ask the experts:

Can I buy ready made fuel lines from anywhere?
Are there any hot tips that someone can give me?
Has anyone got any valuable experience that they could share to help on this one?

Help/ideas would be appreciated please, never done fuel lines before so I can only guess what works!

Cheers, sam.

I was thinking copper was the way to go for mine if I do them as it wont rust and its easy to bend to shape!

Still be a right pain to fit though, and I'd have to swage up the pipes for proper fittings or fit bits of rubber for the complex bits anyway.

Tbh what I'm asking is:

Will anyone have a problem with proper rubber hose assuming it's well fitted?

Cheers!

From what I have seen / heard, rubber / flexible is fine as long as they are secured at regular intervals.

I know from LPG fitting that there is a recommended distance at which flexible pipes need to be attached to the shell.

I had to redo mine in a hurry, all I did was buy the hose from Halfords (was a Sunday), pin it regulary, job done.

The wagon has not had an MOT since so I don't know if there will be a problem - let you know in January.

copper with rubber for the fitting would be the way I would go. , dont need to swage the ends- hose clips will do.

Hello.

So this week I need to find/make up some fuel lines.

Does anybody know the spec on the fittings?

There are 2 at the tank, 2 at the filter, 1 at the fuel rail. The fuel rail return is just hose clipped.

The 3 tank and rail fittings are them same, and the 2 filter fittings are same.

The filter MIGHT be m16x1.5 but only because it looks similar to the fittings on the power steering pipes, and rover shared everything. The other 3 smaller fittings are perhaps some obscure imperial size, maybe a 1/4" but finer than BSP for sure.

If anyone knows the answer or can find out it would be a great help, and save me some time!!

Thanks, sam.

Hello.

So I sorted the fuel lines last night.

I apologise for going against some peoples ideas, but i decided to use rubber hose, for reliability and ease of fitment.

The fittings are m12x1 at the tank and fuel rail and m16x1.5 at the filter.

These, it turns out, are quite rare threads, so the hydraulics people didn't keep them in a hose tail.

As such, I fitted 3/8bsp loose nut hose tails with the appropriate adaptor for each thread. It worked out a neat solution and is easy to service if necessary.

I managed to get the gear for 40 quid, that's 10mtrs of 8mm bore fuel hose, 5 hose tails, 5 adaptors and 10 zero clips.

Started her up, no leaks

Cheers!