Sylvie Willis
Installing a marine fuel tank with foam is a process that requires careful consideration and a good understanding of the potential issues. While some boat manufacturers use foam to hold the tank in place, there are concerns about the impact of foam on the longevity of the tank. Foam can trap water against the tank, leading to corrosion and premature failure. Therefore, it is essential to understand the advantages and disadvantages of using foam and to carefully follow best practices for installation to avoid future problems.
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What You'll Learn
Prepare the tank and boat for installation
Before installing a marine fuel tank, it is important to prepare the tank and boat to ensure a smooth and safe installation process. Here are the steps you should follow:
Firstly, determine the best placement for your new marine fuel tank. It is recommended to place the new tank in the same location as your old tank, considering the vent and fuel hose connections. Ensure that the tank is not installed too deep in the bilge, preventing constant contact with bilge water. If your tank is more than two feet wide, you may need to add frames under the deck to support the weight and prevent sagging.
Next, gather the necessary tools and materials, including a tape measure, flat-blade screwdriver, pliers or wrench, stainless steel pipe fittings, grounding wire, hose clamps, and fuel-resistant seal compound. It is also important to have personal protective equipment, such as gloves and eye protection, when working with fuel systems.
Now, let's prepare the tank itself. If your tank has a moulded vent, thread a hose barb into the vent to ensure proper ventilation. If your tank does not have a moulded vent, simply thread a hose barb into the tank's fuel withdrawal point. Apply a fuel-resistant seal compound to the threaded areas to prevent leakage.
At this stage, you should also connect the grounding wire to one of the terminals at the base of the tank's fill neck. This will help dissipate any static electricity that may build up in the fuel system. Secure the wire with a stainless steel split ring lock washer and screw fitting. Ensure the grounding site is unpainted metal for effective grounding.
Finally, prepare the boat for installation by ensuring the stability of the surface where the tank will sit. Use the hull stringers to support the tank and never place it directly on the bottom of the hull. If you are installing the tank on a bare plywood deck, you may need to build a new deck to ensure a secure installation.
By following these steps, you will have effectively prepared both the marine fuel tank and your boat for installation, ensuring a safer and more efficient process.
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Use the right materials and tools
When installing a marine fuel tank with foam, it is important to use the right materials and tools to ensure a safe and effective installation. Here are some key considerations:
Firstly, determine the type of fuel tank you will be installing. Common materials for marine fuel tanks include aluminium, stainless steel, fiberglass, and plastic (specifically polyethylene). Each material has its own advantages and considerations. For example, aluminium is corrosion-resistant in air due to the formation of an aluminium oxide layer, but it can corrode if water becomes trapped between the tank and its mounting surface or strapping. Stainless steel pipe fittings should be used for the fuel supply, and it is important to avoid mixing different types of metals.
Next, consider the tools and materials needed for the installation process. This may include items such as a tape measure, flat-blade screwdriver, pliers or wrench, hose clamps, vent hoses, gasoline and diesel-resistant seal compound, grounding wires, and hose barbs. Additionally, if using foam, you will need to choose between different types of foam, such as 2-pound or 4-pound density foam, and ensure you have the necessary equipment for mixing and applying the foam.
When working with foam, it is crucial to follow the manufacturer's instructions and take the necessary safety precautions. Wear protective gear, including gloves, eye protection, and a respirator, to avoid contact with the chemicals. It is also important to work in a well-ventilated area to avoid inhaling fumes. Before foaming, ensure the tank is securely blocked in all directions to prevent it from moving during the curing process. Use a rubber block or similar material to keep the tank in place.
Additionally, consider the environment in which the fuel tank will be installed. If the tank will be exposed to sunlight or high temperatures, it may affect the curing time of the foam. Keep in mind that some materials, such as epoxy coatings, may be more suitable for certain environments than others. For example, epoxy coatings can provide additional protection against corrosion and moisture. However, some sources suggest avoiding epoxy coatings as they can still be susceptible to blisters, cuts, and scratches, allowing moisture to become trapped and cause corrosion.
Finally, be mindful of any specific guidelines or regulations that may apply to your installation. For instance, boats with engines built in 2012 or later must use specific types of tanks and fuel lines if the tanks are mounted below decks. Additionally, follow safety guidelines, such as those from the Coast Guard, which require the use of two hose clamps to secure fuel hoses.
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Ensure the tank is secured and stable
It is important to ensure that the tank is secured and stable. This can be done in several ways, depending on the material of the tank and your preferences.
Firstly, you should ensure that the tank is placed on a stable surface. Use the hull stringers and avoid placing it on the bottom of the hull. If your tank is made of aluminium, it is important to ensure adequate airflow around all surfaces to prevent corrosion. Severe corrosion occurs when water is trapped between the tank and another surface, so avoid using materials that absorb moisture, such as foam. Instead, use non-absorbent materials like high-density neoprene or plastic, and completely bond it to the tank. You can also glue the insulator to the tank using an adhesive/sealer.
Additionally, you can secure the tank using brackets or tabs that are screwed to the hull. Another option is to weld tabs onto the tank and secure them to the stringers of the boat. If your tank is made of polyethylene, you must install it with sufficient clearance to allow for a three-percent expansion. This can be achieved by using retaining straps and foam pads to secure the tank in place.
When securing the tank, it is important to avoid using foam if possible, as it can cause premature failure of the tank. Over time, water can get between the foam and the tank, creating pinholes that leak gas. Additionally, foam can speed up the corrosion process by trapping water against the tank.
Make sure to follow safety guidelines, such as using only stainless steel pipe fittings for the fuel supply and connecting an earth-end-ground wire to one of the terminals at the base of the tank's fill neck.
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Avoid common issues and mistakes
To avoid common issues and mistakes when installing a marine fuel tank with foam, consider the following:
Firstly, it is important to note that some sources advise against using foam around a boat's fuel tank. Foam can hold water, which can eventually lead to premature failure and corrosion of the tank. Water can get trapped between the foam and the tank, creating pinholes in the aluminium, leading to gas leaks. Therefore, it may be advisable to secure the tank in place with brackets or tabs screwed to the hull instead of using foam.
However, if you decide to use foam, it is crucial to ensure that the tank is completely secured and blocked in place before you start. The foam will expand, and if the tank is not blocked level, it may lift the tank out of position. It is recommended to block the tank in all directions with a 1" thick rubber block and put a 4" wide tape around the top of the tank as a levy. Additionally, you should cover the top of the tank with plastic before pouring in the foam.
When mixing the foam, start with a small sample to test how fast it foams, as the warmer the temperature, the faster and farther the material will expand. It is also important to note that you should not use foam if there needs to be space left for expansion. Foaming the corners may not allow for this expansion and may cause the tank to buckle.
After the foam has cured, it is essential to trim it and apply a substantial epoxy sealer to prevent water from seeping through and causing corrosion. You should also consider coating the tank with an epoxy-type coating or a product like 'Gluvit' to add to the fuel tank's longevity.
Finally, be prepared for a messy process and take your time. You can do it in stages over a couple of days if needed.
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Test the installation and fix any leaks
Once you have installed your marine fuel tank, it is important to test the installation and fix any leaks. This is a crucial step to ensure the safety and functionality of your boat. Here are some detailed instructions to guide you through the process:
Before you begin, ensure you have the necessary tools and safety equipment. You will need items like a tape measure, a flat-blade screwdriver, pliers or a wrench, and a leak detection kit or soapy water. It is also recommended to wear protective gear, such as gloves and eye protection.
Firstly, inspect the entire installation for any signs of leakage. Look for any visible fuel or oil traces on the tank, connections, hoses, or surrounding areas. Pay close attention to the seals, clamps, and fittings as these are common areas for potential leaks. If you notice any wet spots or discolouration, it could indicate a leak.
Next, perform a pressure test on the fuel tank. This can be done by pressurising the tank to 3 PSI and then using soapy water or a leak detection solution to check for air bubbles. Apply the soapy water around seals, connections, and fittings. If you notice air bubbles forming or soapy water being pushed out, it indicates a leak. This step should be done carefully, and if you are unfamiliar with the process, seek professional assistance.
If you identify any leaks, the next step is to fix them. Depending on the location and severity of the leak, you may need to tighten connections, replace seals or hoses, or make adjustments to the installation. Always refer to the manufacturer's instructions or seek advice from a marine technician if you are unsure. When making adjustments, be cautious not to overtighten fittings or hoses as this can also lead to leaks or damage.
After making any necessary adjustments or repairs, repeat the inspection and pressure test to ensure that the leaks have been resolved. It is important to be thorough and patient during this process to ensure that all leaks are identified and addressed. Remember to use the soapy water or leak detection solution during each test to accurately pinpoint the leak locations.
Finally, once you have confirmed that all leaks have been fixed, clean the area, and ensure that there are no traces of fuel or oil left behind. This helps to prevent any potential safety hazards and keeps your boat in optimal condition. Proper maintenance and regular inspections of your marine fuel tank will help extend its lifespan and ensure safe operations.
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Frequently asked questions
Brackets or tabs screwed to the hull can be used to secure the tank in place. Some people also use retaining straps and foam pads.
Foam can hold water, which can eventually cause corrosion and premature failure of the tank.
Block your tank in all directions with a 1" thick rubber block. Then, put a 4" wide tape around the top of the tank and cover the top with plastic. Mix the foam in a 2-gallon bucket until it turns colour, then pour it under the tank, making sure the tank is blocked down and level.
A two-part marine foam is typically used. Some sources recommend using 4lb foam, while others suggest using 2lb foam.
Ensure that the tank is installed on a stable surface, such as the hull stringers, and not on the bottom of the hull. Use stainless steel pipe fittings for the fuel supply, and avoid mixing different types of metals.
