I brought a bunch of tools home so I could work on making a new tank-to-fuel-pump line in relative warmth. I was exceedingly careful with measurements and came up with one I THINK will work. In order to get those measurements right, I did the pump end first, which is a 90-degree bend. That allowed me to place it on the figure in the instructions (27iS-04 Figure 2) to get the reference point for a 20 29/32" mark, which is the beginning of the bend line for the tank end. Then I put the fittings on and flared that end.

Of course, now I can't use a spring bender to make this bend and if I'd made the bend first I wouldn't be able to get the collar on before flaring the tube.

What I was able to do is put the whole thing in a small Imperial tube bender to at least START the bend. I didn't get it quite right, but I got it pretty close.

So where did that nick come from? One of the suggestions the last time I made (remade, actually) this line was to put a bulkhead fitting on and use that for leverage when making the bend. It's possible that it put pressure on the collar which dug into the soft aluminum; I just don't know. But as I said earlier, this is the second nick I've discovered on this line (one I might've made when tightening a B-nut) so I'm going to keep a close eye on this to see if I'm missing anything.