[s-cars] DYI fuel line replacement BTDTs?

[Sean Douglas]

Peter:

I researched this about 3 months ago, when I found a pinhole leak in the
return fuel line on my S6. The dealer will only sell all 3 pieces
(supply, return and evap) for something like $400 CAD.

I too wanted to fabricate some metal lines, so I bought a flaring tool
and a bending tool from the local auto supply. I tried practicing the
flare on some spare pieces of fuel line and for the life of me, couldn't
get a nice flare. The flaring tool is a fairly cheap one and I could not
find a decent flaring tool unless I spent upwards of $300, they all seem
to be in the $50-$100 range and are of the same quality (cheap).

I gave up and ended up cutting out the bad section and splicing in a
rubber line, I will likely just buy a new set from the stealer before
winter sets in.

If you do decide to make your own lines;

- the fuel line is 8 mm and its hard to find a supplier, 5/16 is pretty
close, but may be an issue
- you will have to re-use the threaded fittings, they are not available
separately
- find a good quality flaring tool
- practice on spare pieces

HTH

Sean Douglas
1997 Audi S6//RS2-spec
1990 Audi 90 quattro 20v


> -----Original Message-----
> From: s-car-list-bounces at audifans.com 
> [mailto:s-car-list-bounces at audifans.com] On Behalf Of Peter Schulz
> Sent: Wednesday, July 06, 2005 9:49 AM
> To: audi20v at rennlist.org; es2 at audifans.com; s-car-list at audifans.com
> Subject: [s-cars] DYI fuel line replacement BTDTs?
> 
> 
> Gents (Any Ladies lurking?)
> 
> Spending time this past weekend under the Mrs' Avant and my 
> 90 have led me 
> to the conclusion that I will have to replace fuel lines and 
> likely some 
> brake lines in the not too distant future.
> 
> For laughs I called Mac at Clair Parts and he said that the 
> factory lines 
> are about $240 EACH for the supply and return lines on the CQ.
> 
> For that money I can buy a really good bubble flare tool and 
> lots of hard line.
> 
> So, any recommendations, BTDT for the tools and the line material?
> 
> -Peter
> 
> 
> 1991 200 20v Q Avant Titan Grey
> 1991 200 20v Q Avant Indigo Mica
> 1991 90 20v Q Red
> 1990 CQ silver (awaiting S2 engine transplant)
> 
> Chelmsford Ma, USA 
> 
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