Bill,
Where is McGiver when he's needed <s>?
Last night I sorted "the facts" and noticed an irregularity, which I have since chased down. I believe the irregularity, if that is what it is, is the culprit.
The balance pipe hose was flatish, or somewhat "pinched" on the fuel cap end. I noticed that when it came out but didn't think twice about it. In the earlier attached photo of three hoses, some of the flatness remains. I had to pinch the pipe into a semblance of roundness to make the photo.
Why flat on one end?
I put my hand into the channel opening on the drivers side. Lots of room there, and a new balance pipe should not be a problem.
I did the same thing on the fuel cap side and - voila - the balance pipe body channel is narrower - my finger just barely will fit.
That seems to be the problem in a nutshell. A new balance pipe won't force through that side.
I don't know if this is a defect that Rootes corrected later, or just what. I can find no indication of a body repair gone wrong, no body repair to the channel at all. The S IV is an early one, #251 that year, so a wild guess is that early S IV's had the problem. Maybe so, maybe not, but the problem is there.
Rootes produced three different Series in 1963, and was gearing up for the Tiger. That's quite a production effort, and I'd expect some changes as the effort progressed over that year.
I looked at the balance pipe arrangement on the S V parts car, and it uses a metal balance pipe. The metal pipe is sturdy and must have been installed before the channel was welded together.
Both sides of the S V channel seem open large enough to present no problem though.
Instead of continued searching for a thin wall 3/8 fuel hose/balance pipe or some substitute such as possibly a brake line, perhaps a metal pipe could be installed in the S IV.
Such a metal pipe would have to bend around the boot spring hinge, and then track up under the balance pipe channel, to be as removed from human/boot interaction as possible, and have less risk of injury.
Alternately, if I could locate a shop that could staple or bind flat a couple feet of one end of a 3/8 fuel line, perhaps it then could be snaked through, and used to pull through a length of non-stapled/bound line.
I'd think that a resulting balance pipe would be more oval or oblong than round on that end, but that should not be a problem if the oval/oblong's opening size is the same size as the round end...
I've attached some photos of the S IV as well as the S V metal pipe.
Thoughts/comments on this situation would be very much appreciated.
Thanks.
Allan