how to connect nylon to rubber fuel line

Connecting nylon tubing to a rubber fuel line typically involves the use of barbed fittings and hose clamps. Here’s a step-by-step guide on how to do this:

Materials You’ll Need:

  • Nylon tubing (of the appropriate size)
  • Rubber fuel line (of the same or compatible size)
  • Barbed fittings (one for each end of the connection)
  • Hose clamps (two for each connection)
  • A hose cutter or a utility knife
  • Safety glasses
  • Protective gloves
  • A flathead screwdriver or a hose clamp tool
  • A heat gun or a pot of boiling water (optional)


  1. Safety Precautions:
    • Ensure you are working in a well-ventilated area away from open flames or ignition sources.
    • Wear safety glasses and protective gloves to protect your eyes and hands.
  2. Cut the Tubing and Fuel Line:
    • Measure the length of nylon tubing and rubber fuel line you need for your application.
    • Use a hose cutter or a utility knife to make clean, straight cuts on both the nylon tubing and the rubber fuel line. Ensure the cuts are perpendicular to the tubing.
  3. Prepare the Nylon Tubing:
    • If your nylon tubing has been stored in a coiled or bent shape, you may need to straighten it. You can do this by gently heating it with a heat gun or immersing it in boiling water for a few seconds. Be careful not to overheat or deform the tubing.
  4. Insert the Barbed Fittings:
    • Slide a barbed fitting into each end of the nylon tubing. Ensure a snug fit.
  5. Lubricate the Fittings (optional):
    • You can apply a small amount of silicone lubricant or a compatible lubricant to the barbed fittings to ease installation.
  6. Connect the Rubber Fuel Line:
    • Slide one end of the rubber fuel line onto the barbed fitting on the nylon tubing. Push it all the way until it is snug against the fitting.
  7. Secure with Hose Clamps:
    • Position a hose clamp over the rubber fuel line where it overlaps with the nylon tubing.
    • Use a flathead screwdriver or a hose clamp tool to tighten the clamp securely. Ensure that it is snug but not overly tight to avoid damaging the tubing or fuel line.
    • Repeat this step for the other end of the connection, securing the rubber fuel line to the second barbed fitting.
  8. Check for Leaks:
    • After securing both ends with hose clamps, visually inspect the connection for any signs of leaks. Run a small amount of fluid through the tubing to check for leaks as well.
  9. Test the Connection:
    • Test the connection by running the fuel system as you normally would, checking for any leaks or issues.
  10. Additional Tips:
    • Ensure that the tubing and fuel line sizes match correctly to prevent leaks or poor connections.
    • If you encounter any issues with the connection, such as leaks, recheck the fittings, tubing, and clamps for proper installation and tightness.

Connecting nylon tubing to a rubber fuel line can be done effectively with the right materials and proper installation techniques. Always exercise caution when working with fuel-related components and materials, and follow safety guidelines and manufacturer recommendations for your specific application.

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