Talk Morgan Forums Morgan Sports Cars Morgan Photo Gallery Silicone fuel filler pipe

In 2010, five years after buying my S1 Roadster, the fuel hose from the filler cap to the tank split and dispensed several pints of the 100 octane I had just bought onto a very hot exhaust pipe. I was lucky not to have been incinerated but embarrassingly I was stranded outside the Ferrari factory in Maranello. I was able to get a replacement Morgan pipe sent by DHL, but at no small cost.

On my return I had a word with the factory about their pipe but there was very little interest and a "It's a Morgan Sir, they all do that" attitude. My suggestion that perhaps all Morgans should not do that and that a car costing north of £40K should be made with better quality materials, was met with anger.

I sent the pipe to a rubber analyst who confirmed that the pipe was made of fuel-resistant NBR rubber, but that NBR rubber is extremely hard and requires to have 10% plastisicer in it. This had been leached out by the alcohol now contained in petrol.

A short internet search found a company that makes seamless silicone fuel pipes. I sent the details to Morgan but there was no interest shown.

Lo and Behold, another five years on, the replacement fuel pipe supplied by Morgan is starting to fail. I contacted the firm that makes the silicone pipes and, with the involvement of Berrybrook Motors, we have had a small number of silicone pipes made. The manufacturer claims they will last the life of the car.

I have had one fitted, and if anyone wants one, Berrybrook have a small number (but could have some more made depending on demand). The fitter said that they might also fit a 4/4 or Plus 4 of the same era as my car. It might also be possible the have pipes made for other models/years if there is enough interest. I have no financial connection with either the manufacturer or Berrybrook Motors.

Good work - and good for you in pursuing this issue.

Our working machines in our business mainly use aircraft type approved hoses and have never failed on 13 years.

My hedge trimmer, purchased in 1994 is fine but my strimmer, from 2004, suffered fuel pipe failure. Ethanol and flexible plastic are not a good combination as the plasticisers are mostly ethanol soluable.

Silicone polymers are generally compatible with Ethanol, but not always with unleaded gasoline....

SAMCO, makers of many silicone tubes for car use state:

Samco Fuel And Oil hose is specially manufactured with a fluorosilicone liner which allows the hose to resist short term contact with oil and petrol fluids, and permanent contact from their vapours, making them ideal for oil or fuel filler neck assemblies or oil breather plumbing.

Note: This hose type is not suitable for permanent fuel or oil transfer (fuel or oil lines), or immersion in fuel or oil.

Recent flurosilicone elastomers may be fully fuel proof, but they are very expensive and it may be cheaper to change traditional hoses on a regular, 3 to 4 year, basis. It is almost impossible to be sure the expensive silicone pipe has been lined with the right flurosilicone needed to make it fully fuel resistant.

Another job before my mammoth European expedition in a few weeks... I purchased a spare from factory when they had the AGM offer (10% off) and hadn't got round to it. Seems that this will be another 5 year cycle maintenance - fuel hose, cam belts, relays etc. etc.

But thanks for all the advice and highlighting the dangers.

Thanks Felix42 for your research work on this problem.

Just fitted new silicon hose from Berrybrook on 2007 plus4. The hose is the correct length so no kink, I can now fill the tank at full speed and hopefully the hose will last.

The only issue I had was that the top of the hose was 45mm internal dia but the fuel filler tube (standard Morgan) was 51mm external dia. It needed vaseline and some easing (I used an old 52mm gauge rear case). I had to use a bent end scriber to pull the hose over the filler pipe and then pull up with some force on the hose while holding the filler cap down.
Price was £118 inc vat & delivery so similar price as the factory hose.
Very pleased.

Glad to have been of help