xflowgolf (Forum Supporter)
xflowgolf (Forum Supporter) SuperDork
3/10/25 7:32 a.m.

Help a rookie out:  How would GRM approach connecting this fuel sender to these fuel lines?  
 

Consider this similar to an LS swap.  Tank is a baffled TBI squarebody Suburban gas tank, with the fuel pump on the sender swapped to an EFI/LS style one.  Tank sender connections look like this:  

The truck being fed by this tank has an 8.1 496 which uses what I've come to understand as basically the same "LS style" fuel system.  The stock tank has been removed, with the forementioned Suburban tank going in its place relocated to behind the axle.  Currently the stock fuel lines along the frame rail look like this:  

So my question for the class; How would you connect A to B? 
 

Cut and flare both ends and use rubber fuel hose and a clamp?

some kind of off the shelf threaded connection for the sender side to adapt to hose? 
 

AN adapter fittings? (How do I adapt these to the cut hardline side?)

Something else entirely? 
 

Engine is otherwise stock and is intended as daily driver and tow duties when done.  

 

Colin Wood
Colin Wood Associate Editor
3/10/25 11:24 a.m.

I'm not super well-versed in fuel system plumbing, but I can give your question a bump.

I'm certain someone here can help you out. smiley

Pete. (l33t FS)
Pete. (l33t FS) MegaDork
3/10/25 12:09 p.m.

Start with replacement fuel lines for the fuel sender's application.  By fuzzy memory, there is a short section of hose that takes the O ring fittings on both ends.

 

If you have a Mastercool flaring kit, you should be able to make 3/8 and 5/16 GM fuel line fittings (like what you have on the sending unit) to thread into those short hoses.  Or, you can get a fuel filter line repair kit, which will come with the nut and a short section of hardline. From there you can adapt as necessary to what's on the chassis.

 

Trivia: The larger of the two fittings is the same as many GM power steering pump/box fittings.  Have used the fuel filter repair kits on several occasions to make adapter bits.

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