Mercedes Mullins
Removing a boat fuel tank can be a challenging task, especially for older boats. It often involves cutting through the deck or cockpit floor to access the tank, which can be labour-intensive and costly. Before removing the tank, it is essential to drain the fuel and disconnect the fuel lines, following safety precautions to avoid sparks. Cleaning the fuel tank regularly is crucial to prevent sludge build-up, which can damage the propulsion system. This can be done by using a fuel tank cleaner, siphon pump, and pressure washer. When removing the tank, one may need to cut around it, take out the fuel sender and pickup tube, and use a lifting strap or chain hoist to dislodge it. It is recommended to consult a professional or seek advice from boating communities for a more tailored approach.
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What You'll Learn
Prepare the boat by draining the fuel tank and disconnecting the fuel lines
Before removing your boat's fuel tank, it is important to prepare the boat by draining the fuel tank and disconnecting the fuel lines. Here are the steps you can follow to do this safely and effectively:
Firstly, if your boat is on a trailer, pull it up a hill to ensure you can get to the very back corner of the tank. If your boat is in the water, you can drive it until the fuel is burnt out of the carburetor and the engine stalls. Alternatively, you can use a fuel pump to drain the tank. A cheap 12v fuel pump can be connected to the fuel line and a gas can to drain the tank. Another option is to use a Seachoice fuel pump, barbs, and fuel hose to create a DIY fuel-tank draining kit.
Once you have drained the tank, you will need to disconnect the fuel lines. It is important to consult your owner's manual to understand your boat's specific fuel line setup. Disconnect the fuel hose leading from the tank at the primer bulb, and secure it with a hose clamp. You may also need to unhook the pink and black wires and remove any screws. If there is any remaining fuel in the tank, it should be treated with stabilizer to prevent it from going bad.
If your boat has internal flotation foam in the hull, it is important to note that it may be soaked with leaked gas. In this case, the foam will need to be removed with hand tools to avoid sparks that could cause an explosion. Additionally, if your boat is more than 10 years old, it is recommended to replace the fuel tank entirely, as older tanks are more prone to cracks, corrosion, and installation issues.
By following these steps, you can effectively prepare your boat by draining the fuel tank and disconnecting the fuel lines, making it ready for further maintenance or repairs. Remember to always put safety first when working with fuel systems.
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Remove the fuel sender and pickup tube
Removing the fuel sender and pickup tube is a crucial step in the process of extracting a boat's fuel tank. This step ensures that you can thoroughly empty the tank and address any issues with water accumulation. Here's a detailed guide on how to tackle this task:
First and foremost, safety should be a priority. Before initiating any fuel-related work, ensure that there are no sources of ignition nearby, including smoking materials. Work in a well-ventilated area to avoid inhaling fumes.
Now, let's begin with the fuel sender. The fuel sender is responsible for monitoring the fuel level in the tank. To remove it, start by unhooking the electrical wires connected to the sender. In some cases, there might be pink and black wires to disconnect, as mentioned by a user. Make sure to take note of the wiring configuration to facilitate proper reconnection during reassembly. Additionally, remove any screws or fasteners holding the fuel sender in place. Be cautious, as the holes might appear evenly spaced, but they are not, so marking the alignment before removal is essential for accurate reassembly.
With the wires and screws taken care of, you can now carefully lift or slide out the fuel sender from its housing. It is recommended to mark the alignment of the fuel sender with the tank, ensuring that it goes back into position correctly during reinstallation. Once removed, set the fuel sender aside safely.
Next, we'll address the pickup tube. This tube is responsible for drawing fuel from the tank and supplying it to the engine. Typically, the pickup tube is located at the rear of the fuel tank. To remove it, start by locating the tube's attachment point to the fuel tank. There might be a clamp or a coupling that secures the tube in place. Loosen or detach this fastening mechanism. Gently pull or twist the pickup tube to detach it from the fuel tank. Be cautious not to damage any surrounding components or connections.
With the pickup tube removed, you now have access to the interior of the fuel tank. This access is essential for addressing any water accumulation issues, as mentioned earlier. Remember to consult boat-specific resources or manuals for additional insights into the fuel sender and pickup tube removal process, as procedures may vary slightly between different boat models.
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Cut the deck to access the tank, if necessary
If your boat does not have easy access to the fuel tank, you may need to cut the deck to reach it. Before you start, plan where you will cut the floor and consider how you will reinstall it later.
Once you have cut the deck, you can remove the fuel tank. After removing the tank, you will need to reglass the deck.
If you are unable to access the tank by cutting the deck, you may need to cut the foam underneath the tank. To do this, you can use an electric chainsaw to cut through the foam.
If your boat has internal flotation foam in the hull that is soaked with leaked gas, be sure to remove it with hand tools to avoid sparks.
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Lift the tank out using a hoist or by jumping on the engine compartment
Lifting the fuel tank out of a boat is a challenging task. One way to do it is by using a hoist. If you have access to a hoist, you can attach it to a welded lifting strap or eye on the tank. If there are no welded lifting points, you can cut two holes in the top of the tank and run the chain through them. Then, apply tension to the chain hoist.
Another method is to remove the engines and jump on the engine compartment. This method was used in combination with a chain hoist in a case where the chain hoist alone was not sufficient to lift the tank. After jumping on the engine compartment together with a friend, the tank eventually came loose. This method may not be suitable for all boat types and configurations, so it is important to assess the feasibility of this approach based on your specific boat setup.
If you have the engines out, you can try jumping on the engine compartment to loosen the tank. Make sure to take necessary safety precautions when performing this task, as it involves physical exertion and working in a confined space. Ensure that the boat is securely supported and stabilized to prevent any accidental shifts or movements during the process.
It is worth noting that cutting the floor may be necessary to access the tank and perform the lifting operation. If you need to cut the floor, plan ahead and consider how you will reinstall it afterward. You can screw or glass "pads" around the perimeter of the floor and fill the cut with a paste mixture of epoxy and glass filler. Finally, use a combination of different-sized mates to cover the crack.
Lifting a boat fuel tank using a hoist or by jumping on the engine compartment requires careful planning and execution. It is important to assess the specific conditions and requirements of your boat and fuel tank setup before attempting any of these methods.
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Dispose of the old fuel safely
It is important to dispose of old fuel in a safe and environmentally responsible manner. Before you begin, consult your owner's manual to guide you through your boat's fuel lines and ensure you are only using containers specifically designed for fuel.
If your boat is on a trailer, pull it up a hill to ensure you can get everything from the very back corner of the tank. Pull the gas line that goes to the engine, put a hose long enough to reach a gas can on the ground, and start a siphon. You can also use a fuel pump to drain the tank. Attach the INLET side of the pump to the hose, connect the OUTLET to a gas can, and throw some alligator clips and wire on the pump to connect to your boat's battery.
If your boat has internal flotation foam in the hull that is soaked with leaked gas, it must be removed with hand tools to avoid sparks. If you are removing the tank from a boat that is over 10 years old, it is recommended that you buy a new tank.
Once you have drained the tank, you can dispose of the old fuel at a designated fuel disposal site, or pump it directly into your tow vehicle's fuel tank to mix with fresh fuel.
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Frequently asked questions
It is recommended to clean your boat fuel tank at least once a year, especially if your boat is dormant for more than a few weeks. Cleaning the fuel tank is also advised before putting your boat in storage for an extended period.
First, insert absorbent cloths into the fuel gauge mounting hole to remove any sludge. Next, fill the tank with alcohol or diluted detergent and let it sit for a few hours. Then, use a siphon pump to suction out the mixture. Repeat this process until the tank is completely clean. Lastly, let the tank dry and put it back in place.
One way to remove fuel from your boat fuel tank is to use a fuel pump. Disconnect the fuel hose from the tank and connect it to the pump's inlet barb. Then, attach a separate fuel line to the pump's outflow barb and place the other end in a suitable container. Finally, connect the pump to the boat's battery to start suctioning out the fuel.
