Fuel System Overhaul – Part 3

Not my fuel line but an example of what varnish looks like in a fuel line.
You can imagine what a 45 years build up would look like.

In a previous post, I described the installation of a new gas tank in the 1964 Barracuda (Fuel System Overhaul – Part 2).  I decided that since the gas tank was bright and shiny, I needed to replace the old, decrepit fuel line that runs from the gas tank, along the underside of the car and up to the mechanical fuel pump.  The old gas tank had been filled with rust and other gunk so I was afraid the fuel line might be plugged or partially so.  

Inline Tubing (http://www.inlinetube.com/) is an online company that sells all kinds of fuel system and brake parts.  Their catalog of parts is very comprehensive.  They even carry a preformed fuel line for my Barracuda.  It is available in Stainless Steel (overkill for me) and OEM carbon steel.   You can also get the fuel line in either 5/16” OD or 3/8” OD.  My little slant six only requires the smaller 5/16” OD. 

I typed in my order for one 5/16” OD fuel line, part number PAF6402 and waited for the delivery.  I wondered how the 10 foot long tube would arrive?  I few days later my question was answered when an extra-large rectangle box arrived on the door step.  I saw that the box was only about 5 feet long so wondered if the fuel line was in two pieces.  On opening the box, I saw that the fuel line was indeed one piece but had been bent into a long radius hairpin.  



It was a simple process to straight out the fuel line into its full 10 foot length.  I laid the old and new lines out on the garage floor and they certainly looked very similar.  On old cars, I’ve learned that there is no such thing as a direct replacement part.  New parts always need some massaging.  The new fuel line was no different.  


You can see some differences between the two fuel lines.
You can’t expect a perfect match to a 45 year old part.
I slowly worked it over the rear axle and through a couple holes in the frame.  The difficulty came in getting the fuel line into the original clips still in place along the length of the car.  Many little tweaks were needed to slowly get the fuel line in place.  Even after the fuel line was in place, I knew there was a lot of tension on the clips.  In fact, I eventually broke two of the clips. 

I found a replacement clip kit from Vans Auto (https://vansauto.com/).  They did not have a specific kit for the 1964 Barracuda but Fuel Line Clip Set 5/16 E-body kit, SKU: CHECLPF56 looked to have the parts I needed.  Vans Auto actually has an eBay store which made ordering and paying simple.  Once the new clip kit arrived, I saw all the parts I needed were included plus a few extras. So now I have a few parts for that Challenger I plan to build some day.  

I used most of these clips even though they are specified for an E-body.




The old clips were a pain to remove but the new ones snapped right in.  I spent some more time adding small bends here and there until the line finally fit nicely along the underside of the car.  I finally connected the fuel line to the fuel tank with some 5/16” rubber fuel line I picked up at AutoZone.  I plan to leave the engine side of the line disconnected until I replace the fuel pump.  I might as well have a completely new fuel system from stem to stern.

Fuel line in place and ready for gasoline.