Rajan Wilcox
Aluminum boats are a popular choice for boat enthusiasts, but many people are unsure about the proper way to access and maintain their fuel tanks. While some boats have fuel tanks installed under the deck or between stringers, others may have them in more accessible locations. In this discussion, we will explore the best practices for locating and maintaining the fuel tank in an aluminum boat, including the importance of ventilation, fuel line considerations, and preventing corrosion. We will also address common concerns such as fuel vapors, tank ventilation, and the impact of choppy waters on fuel tank access.
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What You'll Learn
Preventing corrosion
Aluminium is a good material for fuel tanks in boats, provided it is properly installed. Proper installation and maintenance can prevent corrosion and leakage. Here are some ways to prevent corrosion in aluminium fuel tanks:
Proper Installation
Aluminium tanks should be installed with good airflow around all surfaces. This allows any stray seawater to drain off and dry, preventing corrosion. It is important to eliminate all points that trap water, as severe corrosion, known as "crevice corrosion", occurs when water is trapped between the tank and the boat. To prevent this, ensure there is a minimum of a quarter-inch of airspace between the tank and the flat mounting surface underneath.
Avoid Rubber and Carbon
Do not use rubber strips or carbon with aluminium fuel tanks, as carbon is cathodic to aluminium and will cause galvanic corrosion. Instead, use stainless steel pipe fittings for the fuel supply, and avoid mixing metals.
Protective Coating
Applying a protective coating to the aluminium surface can help to prevent corrosion. Before applying the coating, ensure the tank is free of grease, oil, and other contaminants. Abrade the entire aluminium surface using an orbital sander with 120-grit sandpaper. Then, apply a two-part aluminium epoxy primer, such as Pettit Marine Paint's AlumaProtect, followed by a polyurethane topside paint like Pettit's EZ-Poxy.
Proper Ventilation
Ensure that the fuel tank has adequate ventilation to prevent the buildup of fumes. This can be achieved through the use of mesh doors or vents in the tank lockers.
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Proper installation
Aluminium is a good material for boat fuel tanks, but it is important to install them properly. Proper installation ensures the tank usually outlasts the life of the boat.
Firstly, ensure the tank is installed in a stable location, using the hull stringers and never the bottom of the hull. The tank should not be so deep in the bilge that it is in constant contact with bilge water.
Secondly, ensure adequate airflow around all surfaces of the tank. This prevents corrosion, as aluminium is self-protecting when it has good air exposure. Avoid using rubber strips as rubber contains carbon, which is cathodic to aluminium and will cause galvanic corrosion. Instead, use stainless steel pipe fittings for the fuel supply.
Thirdly, consider applying a protective coating to the aluminium surface before installation. This can help to prevent corrosion and extend the life of the tank. For example, you can use an aluminium epoxy primer followed by a polyurethane topside paint.
Finally, ensure the tank is properly vented, especially if it is located under a deck or in an enclosed space. This will prevent the build-up of fumes and minimize the risk of fuel vapours escaping.
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Tank ventilation
Ventilation is a critical aspect of fuel tank installation in aluminium boats, ensuring the proper functioning of the tank and the safety of the boat. Here are some detailed instructions and considerations for effective tank ventilation:
Ventilation Requirements
All fuel tanks require ventilation, regardless of the application. As fuel is consumed, air must be able to enter the tank to prevent fuel starvation, which can cause the engine to shut down or fail. Additionally, ventilation helps to prevent the buildup of fumes, which can be hazardous.
Ventilation Design
The design of the ventilation system is crucial. A typical vent line runs across the top of the tank and then angles upward to the vent fitting. It is important to avoid sags or traps in the vent line, as these can cause fuel to puddle and block the vent. The vent should be positioned as high as possible on the boat to prevent water ingress, and it should be Coast Guard-approved. Perko's through-hull vent and Attwood's 90-degree P-trap fuel tank vent are examples of sophisticated designs that include features like integral splash guards and baffle chambers.
Ventilation in Enclosed Compartments
If the fuel tank is enclosed, such as under a deck, ventilation becomes even more critical. In this case, natural ventilation is required, unless the space is open to the atmosphere. You can achieve ventilation by installing a vented cap or cutting holes in the enclosure and installing clamshell vents. Ensure that the vents are positioned towards the bottom, as fumes are heavier than air and will collect at the lowest point.
Fuel Surge Protection
Consider installing a no-spill valve or fuel surge protector to prevent fuel from spewing out of the vent when filling the tank. This is not only environmentally friendly but also helps to prevent fuel stains on the hull.
Ventilation and Fume Considerations
Ventilation is particularly important if there are sources of ignition present, such as battery sparks. In such cases, additional ventilation or a fire extinguisher may be required to mitigate the risk of fumes igniting. Choppy water conditions can also stir up fumes, leading to increased venting, so be mindful of this when boating in rough waters.
Compartment Vents
In addition to tank ventilation, consider venting the compartment housing the tank. This can be achieved with a blower and hoses, with one facing forward and one facing rearward, to ensure adequate airflow and the safe dissipation of fumes.
By following these guidelines and considering the specific requirements of your aluminium boat, you can ensure effective tank ventilation, contributing to the safe and efficient operation of your vessel.
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Fuel line length
The fuel line length for an aluminium boat depends on several factors, including the type of engine, fuel flow rate, and the specific design of the boat.
For example, the engine flow rates of 6 cylinder 6BTA or 6CTA Cummins engines are typically between 250-450 HP, which can be used as a basis for comparison with other engines. The fuel flow rate for a 250-450 HP 6-cylinder diesel engine with an inline injection pump is about 1 gallon per minute (GPM) or 60 gallons per hour (GPH).
The length of the fuel line can impact the performance of the fuel pump, as longer lines can result in line loss and reduce the suction capability of the pump. However, this issue can be mitigated by using heavier power cables or a good primer bulb to compensate for the extra length. Additionally, it is important to consider the height difference between the fuel tank and the fuel pump, as pressure is determined more by height than length.
When determining the fuel line length, it is crucial to consult appropriate professionals and consider the specific design and requirements of your aluminium boat.
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Fuel tank coating
Aluminium is a good material for fuel tanks in boats. However, it is important to ensure that the tank is properly installed and coated to prevent corrosion and leaks.
Before coating, the aluminium surface should be prepared by removing any dirt, grease, and oil. Acid etching the surface with a product like Alumaprep can help to buy some application time, as aluminium begins to oxidize as soon as it is stripped to bare metal.
There are several coating options available for aluminium fuel tanks. One option is to use a coal tar epoxy paint, which is a common practice in the marine industry. Coal tar epoxy will seal the surface, but it is important to avoid using old rubber for mounting pads as the carbon black in natural rubbers can cause corrosion. Instead, use solid neoprene.
Another option is to use a two-part aluminium epoxy primer, such as Pettit AlumaProtect, followed by a polyurethane topside paint like Pettit EZ-Epoxy. This type of coating is effective in protecting aluminium airplane components and provides an aesthetically pleasing finish.
Other coatings mentioned include Interlux "Glass Flake", an epoxy barrier coat used to prevent blistering on fiberglass, and GLUVIT, an American-made two-part epoxy.
Proper ventilation is also critical to preventing corrosion. Ensure that the tank has plenty of airflow and is not in constant contact with water.
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Frequently asked questions
Accessing the fuel tank in an aluminum boat depends on where the tank is located. If the tank is under the deck, you will need to remove the deck to get to the tank. If the tank is in an enclosed space, you may need to open or remove the enclosure to access the tank.
Before attempting to access the fuel tank, ensure that you have adequate ventilation to prevent the inhalation of fumes. It is also important to avoid using any electrical or spark-generating items near the fuel tank to mitigate the risk of fire.
Regularly inspect the fuel tank for any signs of corrosion or leakage. Check the fuel fill hose for any dry rot or seepage and ensure that inspection ports are preventing seawater from entering the tank. It is also recommended to periodically pour off fuel into a clear jar to inspect the gas color, water content, and debris.
