Regan Brown
If you're experiencing issues with your Smoker Craft boat, you may need to repair the fuel tank or gauges. While there is limited information specific to Smoker Craft boats, general advice for fuel tank and gauge issues on boats includes troubleshooting the fuel gauge by checking the wiring and ground connections, and testing the gauge with a resistor. If issues persist, you may need to replace the gauge or sender unit, which involves disconnecting the wiring and removing the holding bracket. For fuel tank issues, a simple solution is to ensure the boat is sitting level and to avoid filling the tank to the top. For more complex issues, it is recommended to consult a certified marine technician or a Smoker Craft dealer, as work done by unauthorised persons may void the boat's warranty.
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What You'll Learn
Cut and braze patches to repair rust holes
To repair rust holes in your Smoker Craft boat, you can cut and braze patches onto the affected area. Here is a step-by-step guide:
First, restore the hull to its original shape. You can do this by hammering out the damaged aluminium or using an auto-body or bucking dolly. Cut away any torn edges to help the aluminium lie flat, and drill stopper holes at the end of each tear to prevent cracking. Next, use 120-grit sandpaper to soften the edges of the aluminium. Remove any paint, inside and outside, with a coarse bristle disc to create a suitable bonding surface. Finish by abrading the surface with 80-grit sandpaper.
Now, prepare the patches. Cut a single piece of Episize™ Glass Fabric for the outside and three pieces in decreasing sizes for the inside. The outer patch and the largest inner patch should be slightly larger than the hole to allow overlap. Lay the patches on plastic and wet them thoroughly with G/flex® 650 epoxy. Brush both surfaces of the hull with the epoxy, working it into scratches and dings. Mix 406 Colloidal Silica with the residual adhesive to fill small holes and create a thickened mixture.
Apply the single patch to the outside of the hole, smoothing it into the thickened mixture. Stack the three inner patches, ensuring no air is trapped, and centre them over the hole on the inside. Once you are happy with their placement, leave the patches to cure overnight. The following day, grind the edges of the patches to remove any roughness. Finally, apply a mixture of G/flex 650 and 407 Low-Density Filler to the patches inside and out, and your repair is complete.
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Clean, sandblast, and cover the area with fibreglass fabric and liquid resin
To repair a fuel tank with rust holes, you can clean and sandblast the area, then cover it with fibreglass fabric and liquid resin. This method has proven to be effective in repairing both gas and diesel fuel tanks.
Start by thoroughly cleaning the area around the rust holes on your smoker craft fuel tank. Ensure that the surface is free of any dirt, grease, or debris. Once the area is clean, you can proceed with sandblasting. Sandblasting will help remove any remaining impurities and create a rough surface for better adhesion. After sandblasting, carefully cover the cleaned and sandblasted area with fibreglass fabric. The fibreglass fabric will act as a reinforcing material to strengthen the repair.
Next, apply a liquid resin over the fibreglass fabric. Liquid resin, also known as epoxy resin, will saturate the fabric and create a durable and impermeable barrier. Make sure to follow the manufacturer's instructions for proper handling and application of the liquid resin. It is important to work in a well-ventilated area and wear the appropriate protective gear when working with these chemicals.
Allow the resin to cure completely according to the manufacturer's recommendations. The curing time may vary depending on the type of resin used and the environmental conditions. Once the resin has cured, you can inspect the repair and ensure that it is smooth and seamless. If necessary, you can sand the area gently to create a flush finish with the surrounding surface.
This repair method utilising fibreglass fabric and liquid resin can provide a strong and long-lasting solution for rust holes in your smoker craft fuel tank. It is important to follow the steps carefully and ensure proper preparation and application for optimal results.
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Use sheet metal and braze over larger holes
To repair a smoker craft fuel tank with sheet metal and brazing, you will need to follow a careful process to ensure safety and a successful outcome. Firstly, it is imperative to thoroughly clean the tank to remove any impurities, as these can cause issues during the brazing process and affect the final result. Use hot water, detergent, and methyl alcohol to rinse the tank multiple times, ensuring that all petrol residues, grease, and rust are eliminated.
Once the tank is cleaned, you will need to address the larger holes. Cut a piece of sheet metal that overlaps the hole by at least half an inch on all sides. You may need to sand or file the edges of the hole to smooth out any rough spots before proceeding. Ensure the sheet metal is free of any rust or corrosion, as this can compromise the integrity of the repair.
Next, position the sheet metal patch over the hole, ensuring it is centred and makes firm contact with the tank. You may need to use a clamp or similar tool to hold the patch in place temporarily. Prepare your brazing equipment, following the manufacturer's instructions for safe operation. Braze the patch in place, ensuring you heat the tank and patch sufficiently to create a strong bond. Allow the brazed area to cool gradually to room temperature.
Finally, inspect your work and ensure that the patch is securely attached and that the brazing has created a smooth, sealed surface. Test the tank for any leaks before refilling it with fuel and ensure that all tools and equipment are cleaned and stored appropriately. This process should effectively repair larger holes in a smoker craft fuel tank using sheet metal and brazing techniques.
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Seal pin holes with a fuel tank liner
To seal pin holes with a fuel tank liner, you must first ensure the tank is structurally sound and free from plastic parts, contamination, loose rust, and old sealers. It is also important to wear gloves and protective clothing to avoid getting the product on your skin.
Next, you will need to clean the tank. Mix a solution of one quart of POR-15 Cleaner Degreaser with one quart of hot water and use it to remove any gum, varnish, or sludge from the inside of the tank. Then, coat the tank with zinc phosphate and etch the metal for better adhesion of the sealer.
After the tank is clean and prepared, you can apply the fuel tank liner or sealer. Spread the product evenly over the pin holes, ensuring that it is applied flat. Once the sealer is dry, it will act as a liner and stop rust, corrosion, and small fuel leaks.
It is important to note that you should follow the specific instructions provided by the manufacturer of your chosen fuel tank liner product. Different products may have varying preparation and application methods.
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Coat the tank with red-kote
Coating the tank with Red-Kote is a popular method for sealing fuel tanks. Red-Kote is a fuel tank sealer liner that can be used to coat the internals of a fuel tank. It is important to prepare the tank properly before applying the Red-Kote. This includes cleaning the tank with vinegar and BBs, as well as degreasing and ensuring it is completely dry.
It is also important to use the correct amount of Red-Kote and to avoid spilling it. A second coat is often recommended, and it is important to follow the instructions on the can. Some users have noted that drilling a hole in the bottom of the tank to drain the excess Red-Kote is not necessary, but rather one should be careful not to use too much product and allow the tank to dry upside down.
To ensure full coverage, one user recommended rotating the tank to prevent the liquid from puddling and using an inspection camera to confirm coverage. This user also applied a second coat and allowed the tank to sit for a week in a warm location before adding fuel.
Another user noted that Red-Kote can narrow the holes for petcocks, so thinning the coating may be necessary. Acetone can be used to slowly remove or wipe away the Red-Kote from these areas, but care must be taken to avoid getting it on the paint.
Overall, Red-Kote is an effective and impressive product for sealing fuel tanks, with many users reporting positive experiences and recommending the product.
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Frequently asked questions
First, test the gauge by removing the wire from the sending unit and applying power to the gauge. Then, take a 240-ohm resistor and connect it between the S terminal and GND on the gauge—it should show E. Next, repeat the process with a 33-ohm resistor, which should show F. If the gauge is working, make sure the wiring from the gauge to the tank is intact. If that works, the sending unit is likely broken. If your ground is bad, fix it. If the ground is good, use a jumper wire to short the sender positive terminal to the ground terminal. If the gauge needle does not show "full", find and repair the break in your sender wire.
Disconnect the wiring from the existing gauge and remove the holding bracket using a nut driver or socket. Then, remove the gauge, install the new gauge, and reconnect the wires.
A simple solution is to remove some fuel from the tank. Alternatively, do not fill the tank to the top, and fill it up just before you go out on the boat.
