Fuel Line Replacement Issue

[CTsalt12]

I am in a bit of a pickle.  My fuel line from tank to engine has been compromised, as I've determined from replacing everything else fuel related and still having fuel delivery issues. I discovered upon inspection that the fuel line (which looks like crap cheapo material) has delaminated.  There is a plastic material lining the inside which has delaminated from the rubber fuel line.  The fuel line is so flimsy I'm also worried it might get flattened by the other big cables in the rigging tube to prevent fuel flow.  It's the type of hose you'd use for an above deck connection.  One of these issues is giving me fuel delivery issues at high speed.

So I figure time to replace fuel line,  no big deal.  I'll tie a rigging line to the hose, pull it out one end, pull the new one in with the rigging line.  Should be half hour job.  Problem is, the hole from the tank coffin box in the hull to the rigging tube outside the coffin box is not wide enough for the 3/8 hose with rigging line tied well to it to pass through. And it's definitely not wide enough for the new stout 3/8 fuel line to pass through with a rigging line. 

I can't get a drill in there to widen the hole without taking off the coffin cover, which I really do not want to do during the season.  Does anyone have any ideas on how to get the fuel line though? 

My second thought was to drill a new hole through from the top of the bilge area and send it through that way, not through the rigging tube.  My fuel separator is inside the deck below the stern boxes, so it would go from bilge to there.  Is that a crazy idea?  So in the picture this would mean the white line would go straight back to the stern.  I know fuel coffins should stay as dry as possible but there is already a drain hole in the bottom from the PO.

You'll see in the pic the white fuel line I am replacing, and how narrow the hole is.  Newer fuel lines are much wider.

[CLM65]

What size string are you tieing to the fuel line?  If the fuel line moves freely, you will not need heavy, thick rope to pull the new fuel line through.  Also, how are you tieing it to the fuel line?  I would poke a hole through one wall of the fuel line, run the string through, and tie a loop knot so that the amount of string outside the hose is minimized.  I think it would be better to keep the same routing path you currently have.

[fitz73222]

1) The fuel line delaminated because of age and Ethanol fuel.
2) Yes, you need to use the class 1, thick walled hose for under deck.
3) If I'm not mistaken, I see a quick connect fitting (looks like a Chrysler outboard style) which is a huge no no under the deck. Needs to be on a 3/8 barb and doubled opposing clamps.
4) The only way to do it correctly is to pull the hatch, the rigging tube should be able to accomodate the larger diameter hose since thats been law for 20+ years and the boat should have come with it. When dealing with fuel systems, there is only one way to do it, sometimes the PITA way. I would not be drilling new holes in the boat as a workaround.

[CTsalt12]

Thanks for the quick input CLM and Fitz. 

CLM-Great idea to put hole through fuel line and tie a knot that way.  That should get it through, as the line moves freely until it hits the hole.  Unfortunately I will have to do it with the new line as well and then cut off the end with the hole. 

Fitz-Thanks for info.  I think what looks like a quick connect fitting is actually a clamp up against the barb and it's misleading.  I will make sure to double clamp going forward though. 

As for #4-The hole will accomodate the new larger diameter hose from looks of the picture, just not with a rigging line tied outside of it .  I think if I use CLM's method I should be able to get it through without drilling or removing coffin.  I'm going to give it a shot. 

[JimInPB]

You might try finding a barb fitting that is snug in the hose, then stick the pull rope inside the barb & tie a knot so that the rope can not pull out of the barb.  Then jam the barb down deep inside the hose.  Top that off with some electrical tape to form a cone shape where the rope & barb now come out of the hose.  Add a little electrician's wire pulling lube, like dyna blue or clear glide & you should have your best chance of success.