Yes, it is suprising how much strength the flares add. I would like to pick up powered metal working tools but, like you say, they are just to expensive to justify for the limited fab work I do...

Haven't gotten much physical work done on the van. I have been designing and detailing all of the coolpack stuff, Shrouds and brackets and pulling together parts for the fuel system.
I posted this in the engine forum so it would get more views.
I just wanted to get these fittings out there incase anyone else is wanting to run steel lines. I know aluminum is the norm but I am nervous using aluminum when I know fuel quality is for shit and the percentage of ethanol is cause for worry. I will be running 1/2" diameter by .035 wall steel hydraulic tubing for all of the van's fuel and return lines.
I will be using YOR-LOK compression fittings from McMaster Carr. They go from the 1/2" steel line to any size pipe thread you could need. I will be using the 3/8th female NPT and running 3/8th NPT male to -8 AN adapters to get from the pump and out to the engine.
McMaster-Carr
These are designed to work with gasoline and have dual ferrules to provide a leak-free seal. No worries running these, they'll work great and they are not expensive.
Mark