What do I need to buy and how difficult is it to replace the stock fuel lines with bigger ones and replace or drill out banjos.

 

It's really easy. Just go and buy some rubber fuel hose that is rated for diesel and up to 20 or so psi and some hose clamps. Remove the old line and install the new one. Shouldn't be hard at all.

 

MonroeDiesel, What is your goal of enlarging your fuel lines?

thanks Jamie

 

Here is a word of advice: don't ever use rubber hose for fuel line of any length on a vehicle. They do not stand up to the vibration, heat, sun exposure, cold, etc. present in vehicle usage. I know they used to be used a lot, but now only in short sections for interconnecting steel lines.

I know of an engine fire started by a rubber hose that gave out after 5 years of perfect service. It just isn't worth it.

 

i know of several engine fires [& seen one in person] caused by ruptured steel HP fuel lines [all on GE FDL series diesel engines]

ge locomotive with FDL series engine burning. the fire i saw wasn't nearly as impressive as that one though.

in the pic in this link, you can see where the HP fuel lines are located.. [u shaped steel line going from unit injection pump to injector nozzle] note the flex lines between the pumps.. on the newer electronic engines, there is 2 sets of lines, and they run a fuel pressure of up to 90psi in them [this older series of engine the pic is of, runs 40-45psi in the flex lines]