Geetings,
I need some specific information. What are dimensions of the fuel hard lines that go to and from the fuel tank. Also, what are the dimensions of the injector hard lines?

Has anyone fabricated these lines as replacements on a diesel engine built after 1989. If so, were you successful and are you willing to share your "how to"?

Thank you,
Kristopher

Forget it. The lines are heavy gauge steel, the ends are silver soldered. Can't be dine at home.

Warning I did not spell check.
Back in the late 1970s there was large Fuel Injection Shops that could make the Hard Lines.

There is no generic lines that fit all. The inside diameter and outside diameter are important as those specs are supposed to be decided uapon per application.

Depending on the shape of the Fuel Injection Hard line ends the ends can be swedgted (cold formed into shape). However when we did this in the Fuel Injection Shop where I worked there was a failure rate of about one out of twenty.

When they failed usually the cracked near where the end was swedged.

This was over 4 years ago but there was a company here in California that sold Indian Pop/Diesel Nozzle Testers that sold blank lengths of the Fuel Injection Hard Line.

I don't recall them selling the ends of the lines that needed to be silver brazed on.

So if you need them you either get used ones, find a shop that makes them or buy them new.

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84 300D, 82 Volvo 244Gl Diesel

For the lines to/from the tank, under the car, this may be a source for a repair section.
[url]https://www.belmetric.com/10mm-brake-fuel-air-line-c-17_186_1170/bl62m10-cohline-p-6540.html[/url
Tools for flaring:
http://www.tooltopia.com/mastercool-71475prc.aspx

However, if it requires any bends, it may require hydraulic equipment. The least expensive route would be trying to find used at a PickNPull, etc...

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Sam

84 300SD 350K+ miles ( Blue Belle )

A fuel line from pick n pull is six dollars......
and it's made to order.

Jeff

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1984 300SD 300,000 miles--two tank WVO setup
2.88 diff & 500SEL anti-squat rear end

Fuel injector hard line and brake line are not even remotely compatible. The ends are NOT brake flares, doesn't matter what tool you use, they wont seal.

A couple of comments about buying these lines. Several years ago, the only hard lines available were straight, not prebent. Bending these heavy steel lines to the precise shape to engage the mounting pads is no small task. I recently bought a hard line from the dealer, and the ends were swaged rather than brazed. It absolutely refused to seal. I ended up with a used line that a lister was kind enough to retrieve from a pick & pull.

Fuel Injection Hard lines have a much smaller inside diameter and much thicker walls then brake lines do.

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84 300D, 82 Volvo 244Gl Diesel

Many injector lines use the same fittings. My 60s alis chalmer's had the same injector lines as my 80's om617

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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

My friend had a go and failed at making successful IP hard lines, however he did get the clever idea to mock them up first from same bore soft copper pipe, then once happy with the shape of the copper lines, go ahead and bend your proper injection line using the copper as a jig / template.

I really want to make my own hard lines for my 606.962 with the lines coming out the plastic cover like some kind of compound turbo Cummins puller!

Did an imag.google.com search = Diesel Fuel Injection Line Steel tubing

Rocken, Tech, diesel, injection, high, pressure, fuel, lines, flexible, test, bench, stand, parts
That place is in Petaluma, California 94954 USA

There is some good pic that show the ID compared to the wall thickness at this site.
Fuel Injection Pipes Diesel Pipes from China manufacturer - Zhangjiagang Renaissance High-precision Steel Tube Co., Ltd
There location is in the PRC.

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84 300D, 82 Volvo 244Gl Diesel

The Rocken prices are high ~$100 per fuel tube = $500 for my engine. Their pop tester is also high at ~$415 vs ~$150 for a similar-looking one from India. I paid <$50 for the pop-tester I made using a better horizontal pump (new) from ebay (for Ford diesel PRV testing).

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1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans

I just posted what I found I was not recommending anyone purchase from them.

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84 300D, 82 Volvo 244Gl Diesel