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240 outrage fuel tank leak

Old 11-19-2020, 10:10 PM
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Default 240 outrage fuel tank leak

Hello, I am wondering if anyone has dealt with a fuel tank leak on a Boston Whaler 240 outrage. It is a 2003 model with an aluminum below deck fuel tank. I discovered a bilge full of gas when I went to get the boat from dry storage, I pulled the plug and drained the gas, I checked hose connections and external fuel filters with no signs of leaking, in the mean time the bilge started filling up again with the boat in my drive way. I have drained the tank now and it looks like I will need to lift the t-top and console to get the deck cover off to access the fuel tank. I have never attempted a repair of this magnitude. Has anyone done this to an outrage 240 before? Thank you in advance for advice/insight on this project.
Old 11-29-2020, 11:47 AM
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I replaced the fuel tank on my 1995 24' Whaler. it was pitted on the bottom in the back. I replaced mine with a 111 gal poly tank and it is why Whaler now only used poly tanks in their boat building. Hardest part was pull the old tank out.
Archie
Old 12-01-2020, 08:06 PM
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Did you have to lift the console/top?
Old 12-02-2020, 06:24 AM
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I had to move my big leaning post to pull my tank so I built a gantry for about $200 to lift everything. Made short work of both the console and the tank.



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Old 12-02-2020, 06:51 PM
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That sure looks like a back saver, thank you for the tip
Old 12-03-2020, 08:51 PM
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I had to remove the center deck panel and the rear deck spashwell. I cut mine up with a saw. Cut the foam out with a pressure washer with 0 degree bit around the tank.





Old 12-03-2020, 08:58 PM
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I did not have to remove the console but did have to slide the deck out from under it a bit. I recored that deck a while back. I got a Moeller poly tank, set it on rubber mats that have thousands of mini feet so water can go under and strapped it in. The 111 tank I found matched the angle of the v in the bottom of the cavity. Been putting non ethanol in it since. Not sure how long the poly will last but let's see that tank try to corrode on the bottom again like the last Swiss cheese one. I did not use any foam and followed Moeller install instructions.
Archie
Old 12-08-2020, 07:09 PM
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Looks great! Thank you for the information, I have not been able to find a plastic tank for mine yet, where did you get the rubber mat?
Old 12-08-2020, 09:16 PM
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They are 24" by 24" squares sold at Lowes for garage floor. Got the idea from Born again Boating on youtube. Lets water through. and easily cut and makes a nice bass for the tank

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