[s-cars] finally lost a fuel line

[Fred Munro]

Mike;

I had the same problem on my S6. Upon inspection I found both the vapour
line and the return line had failed but the high pressure line was still
pristine. Go figure. I replaced the two failed lines with Nylon 11 fuel line
and cleaned and POR-15'd the high pressure line. The tubing diameter is 8
mm. I used specialized compression fittings to mate the Nylon 11 line to the
stubs of the steel lines at the front and back of the run. Working like a
charm so far. You have to make sure the Nylon line is not too long - it
can't support itself like steel line and will sag between the rubber mounts
if it isn't the right length.
When the lines failed on the S4 I owned before the S6 I replaced them with
generic galvanized steel line from a local flaps. That line was corroding
after the first year, so I went with the Nylon line on the S6. The OEM line
is actually well made - copper plating over steel, with an epoxy topcoat
over the copper plating. If it wasn't for the rubber mounts holding salt
water against the line it would probably last the lifetime of the car.

HTH

Fred Munro
'97 S6

-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com] On Behalf Of Mike Fitton
Sent: May 11, 2010 1:48 AM
To: s-car-list at audifans.com
Subject: [s-cars] finally lost a fuel line

Guess it was all the salt this winter.  Have a slow leak just forward of 
the rear tire around that one clip.  I'm not opposed to going totally 
overboard on this one, so what are my non-temporary outlast-the-car options?

I see that I can order a new set of three from the dealer for ~$270.  I 
assume they come with shipping bends...no big deal.  What I am worried 
about with that is that they may bend up too much at the ends for the 
tank/engine and I won't be able to get them in the car without a lift.

Or maybe I'll just replace the very bottom parts with new piping and 
flares.  Anyone know the ID/OD?  Any reason I can't use stainless steel?

Any thoughts on going braided?

Basically what's the awesomest way I can repair this without involving 
fuel cells/surge tanks/heat exchangers?  Anyone dare me to run them 
through the cabin, Subaru style?

-Cheers!
Mike
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