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On my '87 Pontiac 6000 wagon currently rolling at 201K miles, a section of the steel fuel line that curves into the fuel filter is rusted pretty badly, as well as the return line.
Having done some research, though nylon fuel line is common in modern cars, its not recommended to use with steel lines, so i am planning to replace them with steel line since the engine is MPFI which uses higher fuel pressure.
The steel lines running to/from the fuel rail are still in good condition so no need to change that out. That section is good up to the two fuel hoses before connecting to the steel section that runs underneath the car. So that may save me some work on line replacement.
I am going to replace the tank, sending unit and fuel pump as well as the fuel filter, so that my fuel system can be top notch. My undercarriage isn't as bad rust-wise which is a good thing. Labor Day weekend will be perfect to get this job done since I will have a 3-day weekend.
My question is, once i remove the old line, would I be able to form and bend the new line to match the original one as close as possible? It shouldn't be too difficult; has anyone ever formed their own fuel line from the OEM? I know a good tube bender tool will be needed and the double-flare tool for the connections.
You can fabricate the new line to follow as closely as possible to the original ... and either splice it in with flare unions or consider using compression unions. Since it's steel line, it's easier, IMO, to use the compression fittings than to flare the tubing.
Another option is to get some pre-formed lines made up by one of the outfits in Hemmings, if you are not keen to fab it yourself.
You *might* find a good set of lines in a boneyard. Might.
Have you checked with a GM dealer? The part may be available over the counter.
For a 25 year old car, I wouldn't bet on it. Thought about the JY, but A-body cars are difficult to find nowadays, and that isn't rusted out. Haven't heard of Hemmings though, I'll check it out. I got some spare tubing that I can practice with but fortunately, the line from the front wheel well to the back isn't that difficult to form so even if its not exactly like the original, it will be close enough. Plus it gives me something new to learn. Thanks for the input!
Just BEND IT with your HANDS - no need for a 'tool' - the lines bend very easily - just do your best and DONE..
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