October 23, 2009 - Of course, the final solution to the fuel rail outlet was simple.
Tap the hole for a 1/4 NPT and screw in a hose barb. However, I was lucky. The 1999-00 fuel rail I'm using has a fairly beefy casting where the damper/regulator plugs in. It's a damper on the returnless 1999-00 fuel system, but for my 1994 system with a return line I had a regulator in place. That's a damper right beside the rail. Anyhow...
All the other rails such as the 2001-05 one above have a much thinner flange design. Would it be enough to tap to 1/4 NPT? Probably. But I'm more comfortable with all that extra metal around mine. With the 2001 version, I might have left the damper in place and drilled/tapped the end of the rail for 1/8 NPT. Not a lot of meat, but it's been done.
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