Senate

I didn't find any pictures of similar projects before I started this project so hopefully this will assist someone out there. This is definitely the largest boat related project I've ever attempted, I did the entire project by myself but it would have been great to have a helping hand. It wasn't very difficult just time consuming.

So I bought the boat about 3 years ago, it's a 2002, and I started smelling gas in the forward hatch a few months back, and then one day when I pulled the cover off I saw gas residue running from the drains in the front of the boat. So I knew what had to be done.

I did some research and found that I didn't have to pull the entire cap off, I could just lift the front and slide the tank out. So I removed the rub rail and all the screws behind it (the majority of the screws broke off when I tried to take them out). I cut through the 5200 or whatever they used with a razor blade, and there were a fews bolts holding the cap on in the forward hatch but all in all it probably took me 4 hours to get the cap lifted and the old tank out.

I found a small rusted spot on the bottom corner of the tank that was the culprit. I emailed Action Craft to see if they had a tank they could sell me, they had a similar tank but the fill cap was moved due to some EPA regulation. So I googled tank manufacturers and found RDS in Perry, FL. I sent them a drawing of my tank and their engineer sent back a quote that was a little cheaper than what Action Craft was selling them for, and my dad works in Perry so I had him pick up the tank and bring it to me so I didn't have to pay any freight. They quoted me 3 weeks but they had it done in 1 week. The cost was around $450 and I believe it was 31 gallons. Highly recommend them.

I put new fuel lines and a new vent in, repainted the forward hatch, bolted the new tank in, lowered the cap, applied tons of 5200 and boat life caulk, put a new rub rail and rope in, filled her up and took it for a spin.

rgarry

You need to coat that tank. Search this forum. Action Craft uses tar but I think there other processes as well.

http://www.thehulltruth.com/boating-forum/10452-coating-gas-tanks-coal-tar-epoxy.html

Flatout71

Nice work

CK Prime

Great thread. Thanks for sharing. We recommend the tank coated for protection but hopefully this new tank lasts you for another 15 years or so. CK Prime

Senate

Well I'm definitely not taking the boat apart again to coat the tank now. I researched it before I put it in and I might regret not doing it later but if I get another 15 years I'll be pretty happy.

LeakinLena

The surface of aluminum oxidizes when exposed to air which protects itself from further corrosion but crevice corrosion will occur where oxygen is not present and eat completely through an aluminum fuel tank. I'm guessing the bottom corner of the original tank that leaked sat in water or never dried out and corroded through. One good method to prevent crevice corrosion is to coat the tank with epoxy paint but if you can keep the tank relatively dry by installing a compartment drain or ventilation louver or an access hatch that allows you to manually dry it off once in a while it will last indefinitely.

r_ventura_23

Nice job. how many gallons tank? What did the new tank cost?

JDBer94

Thanks for posting.

Senate

31 gallon and it was about $450

Senate

Yeah basically what I think happened is some leaves or something got in the front of the tank and allowed moisture to sit there. The tanks sits on 1/2" rubber pads so there is some airflow but I think something made its way underneath the tank and got wedged in there.

r_ventura_23

My tank is 35 gallons. Where did you get the new one?

LeakinLena

Sounds about right. If you can keep it reasonably dry tank will outlast the boat.

Senate

A company called RDS in Perry, FL.