Fuel lines are available in a variety of materials. The standard fuel line on a vehicle is a rubber tube or flexible metal tube. Some fuel lines are hard metal. The typical fuel line on outboard motors and lawn equipment is a clear plastic tube. You can splice a single line into two lines easily. A few tips for the project include using the proper materials, cutting the lines, and simple methods for splicing the lines.
Splicing a plastic fuel line requires using the right connectors and fasteners. Fuel lines come in multiple sizes ranging from 1/8 inch to 5/16 inch. Larger diameter tubing is available for industrial use. The tube size is usually printed on the tube. However, some original equipment fuel lines may not reflect the size. The connections between a splice need to be the same size and material as the tubing. Plastic connectors are available in Y-, T- and elbow-joints. Fasteners hold the tube onto the connector. High-pressure lines should use any type of hose clamp for the fuel lines. Standard fuel lines are held in place with the barbs on the connector. Pinch clamps can be added for additional security.
Cutting plastic fuel lines is simple. The first thing you should do is to depressurize the system. Consult your owner's manual for instructions on how to depressurize the system. Cutting the plastic line requires a clean, smooth cut. Small diameter plastic tubing can be cut with simple metal shears. Larger diameter or hard plastic line requires more finesse. A small PVC pipe cutter provides a clean edge after cutting. You can use a hacksaw on larger tubes as necessary. However, sawing leaves a very rough edge. You should sand the ends with a 120-grit or 220-grit sandpaper to remove the burrs and smooth out the connection.
Plastic tubing is relatively simple to splice. After cutting the lines where needed, you slide the hose clamps onto the tube if you will be using any. Insert the plastic connector to the original lines and add the additional line to the third end of the Y or T connector. The last step is to tighten down the hose clamps and the line is secured. Plastic, however, is not very flexible making pushing the connector into the tube difficult. Heat the tube with warm or boiling water to expand the plastic before pushing the connector into place. Do not use heat or lubricating spray as that will weaken the plastic.
