Assembling a Fuel Rail

The Parts (see diagram below):

• Fuel Rail Body:  The main part of the fuel rail that carries fuel to the injectors.  Made from silver anodized aluminum, the Fuel Rail Body can be cut to almost any length.  A "T-Slot" runs down the entire length of the Fuel Rail Body.  This slot is used for mounting the rail by various means using our adjustable mounting brackets or building your own brackets.  The head of a bolt can fit into the T-Slot and will not rotate, this enables strong connection to our mounting Strut or your custom made brackets.
• -6 AN Fitting:  This fitting connects the Fuel Rail Body to standard -6AN fuel fittings available at any performance auto parts store.  Two O-rings seal the -6AN fitting against the rail for a leak-free connection.

• End Cap Cover: The cover is designed to cover and hold the –6AN Fitting and keep the fitting from being pushed out under fuel pressure.  It also creates a very clean looking fuel rail. 

• T-Slot Nut:  The T-Slot Nuts slide right in the T-Slot and then lock in place on both ends of the Fuel Rail Body with 2 8/32" set screws.  A 8/32" cap screw threads into the T-Slot Nut to secure the End Cap Cover in place.  T-Slot Nut’s can be used for other things as well, from holding Plastic Wire Loom to Vacuum Logs!
• Fuel Rail Strut:  A highly adjustable mounting device to connect the fuel rail body to your engine.  The Strut connects to the Fuel Rail Body with two bolts.  The heads of the bolts slide into the Rail's T-Slot and are then secured with nyloc nuts.  The slot in the Fuel Rail Strut accepts hex head bolts and recesses the heads for the cleanest look.

Important Notes:

• Please note that our fuel rail system relies on a solid mounting point using the Fuel Rail Strut or your custom bracket.  An insecure strut or bracket can cause leaks around the fuel injector o-ring.  It is critical that you are confident in the mounting strength.
• You should always use at least 1 Fuel Rail Strut or custom bracket for every 2 injectors on a fuel rail.  Struts/brackets should be as evenly distributed and centered as possible.
• Extrudabody provides stainless steel hardware and anodized aluminum parts.  This combination is great to minimize corrosion and keep your system working and looking good.  But, if you over tighten stainless screws and bolts into aluminum threads, you can mar the threads.
• Always carefully test an assembled fuel rail for leaks prior to starting your vehicle for the first time.  Keep a properly-rated fire extinguisher close at hand when testing.

Assembly Steps: (Your rail may come partially assembled.  If so, skip steps as needed.)

1. Once your fuel rail has been drilled to accept fuel injectors (see our technical article on drilling), you should ensure that the inner fuel passageway is completely free from debris.  Compressed air or water are both fine for cleaning out the passageway. 
2. For each Fuel Rail Strut (or custom mounting bracket) you plan to use, insert the heads of two Hex Bolts T-Slot Nuts into the Fuel Rail's T-Slot.  Remember to use at least one strut/bracket per 2 fuel injectors.
3. Attach your Fuel Rail Struts or custom brackets to the Fuel Rail Body using provided Nyloc 6mm Nuts.  No Loctite is needed.  Very lightly tighten the nuts to allow the strut to move freely.  The nuts will be fully tightened after installing injectors and mounting the rail to your engine.
4. Place two O-rings in the groove of each -6AN Fitting (2 for each end of the rail).
5. Smear a light coating of motor oil around the O-rings and insert the -6AN Fittings onto each end of the Fuel rail.
6. Insert a T-slot Nut in each end of the fuel rail.  Make sure the threaded hole faces out from the Fuel Rail Body.
7. Place the End Cap Covers on each end of the Rail and secure using the set screws provided (8/32" x 0.25") with 1 or 2 drops of blue Loctite®.  Tighten just over hand-tight.  Do not over-tighten - let the Loctite keep the screws in place. 
8. Install two T-Slot Set Screws in each the T-Slot Nut.  Use a drop of Blue Loctite on each screw and screw with sufficient force so that the End Cap Cover is fully secured to the Fuel Rail.
9. You are not ready to mount your fuel rail to your throttle bodies.  See Mounting Fuel Rails