Anyone have experience with mild steel "Bundy" fuel line? Say in 5/16" to 3/8" sizes. How easy is it to bend without kinking, say with a run-of-the-mill Home Depot hand bender (like you'd use for copper water line)?

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2004 Buick Lesabre Limited, Gran Touring
Bone Stock

1998 Buick Lesabre Limited, Gran Touring
Retired

I've had reasonable luck using and bending them. Using reasonable care with the bending, you should do fine with them.

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Bending and flairing mild steel tube is pretty easy. Just use good tools. Make you bends with the correct inserts in the tool to keep the tube from forming a kink. Same goes with the flair tool. I've been able to do mild steel, aluminized steel, and stainless steel up to 3/8" with no problems at all.

If you can, use seamless aluminized steel tube (sold as replacement brake lines at hydraulic supply places) instead of just plain steel. The aluminum coating will keep the tube from rusting longer. It doesn't cost any more than plain or galvanized.

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The hand bender at Home Depot (I know which one you're talking about) is a little less than you'll need for 3/8", but might do some slight gradual bends. You'll want to increase your bend radius a bit to use it with steel.

(No rust in CA, no worries about the outside of the line, but if it's important, I wouldn't use it for fuel, as there's always a little moisture in fuel.....I like Curt's suggestion above)

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X4 Just be careful when bending the 3/8".

A decent and inexpensive tube bender can also be purchased at Harbor Freight. For use by the guy who will only occasionally need one.

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A very old trick that also is helpful, fill the line with sand while bending, it will help prevent kinks.