This post is titled Adventures in Fuel Lines...
I bought a fuel line kit from a vendor thinking that would save me some time, this was purchased almost four years ago. When I went to install the lines, nothing was very close to fitting, plus the barbed ends on the hard lines were all 3/8"s which wouldn't work with the fuel rail spring locks, or the return line on the EFI tank I had previously installed. My neighbor next door has the same kit and his went in with just minor tweaking, but the bends in my lines were not the same and after trying hard to get them to work I decided to make my own fuel lines.
Now, I have this knack of purchasing something for my bronco only to have that item updated/improved within a short time after my purchase. This was the case with both my BCB EFI tank (non AN fittings at the tank) and the fuel lines. One issue was the straight send and return lines on the rear tank. The fuel hose would kink in the 90 degree bend to the hard lines. Not wanting to drop the rear tank and weld on fittings so AN fitting could be used (which is what the new tanks are set up for), you will see in the pictures what I came up with. Both the main and aux tanks have the vent lines plugged, I have not had issues that some have had with fuel smells and such (side note: with the cover off of the vapor tank behind the drivers seat I could see that it would fill up with gas often, and I felt like I had a molotov cocktail in the cab of the vehicle and that is why I removed the stock vapor system). Several trips to different parts stores provided 5/16" barbed fittings so I could connect the hard lines with the fuel rail spring locks and as well as the return line on the rear tank. I did need an adapter for the 3/8" to 5/16" send hard line barb. I am using my aux tank as a large fuel can with the EFI setup, so I am using a Carter fuel pump to transfer gas into the return line when the main tank gets low. I was limited as where to mount the Carter as I wanted it protected by the BCB belly pan/skid plate. A 3/8" barb with a 5/16" fitting for the T fitting return line was purchased at Napa. Once again, hose kink issues combined with operation of the E brake made for a tubing bender solution allowing full operation of the E brake. I also used hard line from the aux tank to the Carter pump to put the fuel filter on top of the frame. I heated and bent the inlet on the Explorer fuel rail to clear the wiring and the firewall (351W and 2"BL), and widened the fuel rail with 5"16 EFI hose for the 351W. I may need to make one more bend in the return hard line on the frame as the return hose wants to contact the body, however I put another hose over the return hose in the area of slight contact (a fuel hose skid plate). I have done this in the past with no issues, but will keep an eye on it. Next is to make all the electrical connections to the fuel tanks and when I get there, check for leaks.
Even though the fuel line kit I purchased didn't work for me, the vendor I bought it from continues to improve designs as the bronco world evolves. I will be buying other products from them in the future. No two broncos are the same in my experience and sometimes stuff just happens. What I learned in making my own fuel lines was well worth it.