Mercedes Mullins
Replacing a fuel tank in a boat is a complex process that requires careful attention to safety. It involves disassembling the boat, removing the old tank, and installing a new one. Before beginning the process, it is important to check for leaks and ensure that the tank is properly secured and plumbed. Old plumbing lines, wires, and hoses should be replaced, and a leak test should be performed to ensure the safety of the boat and its passengers.
| Characteristics | Values |
|---|---|
| When to replace | When the boat's fuel tank gets old and may be at risk of leaking |
| What to do first | If the tank was foamed in place, remove the foam as it is likely to be saturated with fuel |
| What to do next | Remove the plumbing running to and from the engine(s) as well as to the fuel fill and vent |
| What to do after | Replace the old plumbing lines and wires |
| What to do with the new tank | Properly secure, plumb, and leak test the new tank |
| What to do after the new tank is in place | Repair or reassemble the boat's structure as necessary |
| How to leak test | Pressurize the tank to three psi (or as per manufacturer instructions), then apply soapy water to all the connections |
| How to identify a leak | Carefully inspect each connection for the presence of bubbles |
| What to do if a leak is found | Re-seat and tighten the connection, then test again |
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What You'll Learn
Removing the old tank
Before removing the tank, it is important to inspect it for any signs of damage or leaks. If the hoses and clamps are original to the boat, they will probably need to be replaced. If you smell fuel and the hoses and fuel sender look OK, have the tank pulled, inspected, and repaired or replaced. If this has never been done, remove the fuel sender, inspect the interior of the tank, and insert a hose so that you can sample the fuel at the very bottom of the tank.
Once the tank has been removed, it is important to dispose of it properly. Do not attempt to reuse the old tank, as it may be damaged or contaminated. Take the tank to a recycling centre or hazardous waste disposal facility.
It is also important to note that replacing a boat's fuel tank is a complex process and should only be attempted by experienced individuals. If you are unsure about any aspect of the process, it is best to consult a professional.
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Replacing the foam
If the tank was foamed in place, a common boatbuilding procedure, and the tank leaked, the foam is likely to be saturated with fuel. This makes it hazardous, so it's important to remove the foam along with the tank.
To replace the foam, you'll need to gain access to the tank without cutting open the deck. This can be done by removing the in-deck fishbox liner, as done by a builder in a case mentioned by *Yachting* magazine.
Once you have access to the tank, you can begin the process of removing the old foam and installing new foam. Be sure to wear protective gear, including gloves and a respirator, to avoid exposure to any hazardous materials. Use a suitable tool, such as a putty knife or a foam-removal tool, to carefully scrape and remove the old foam from around the tank. Vacuum the area to ensure all loose foam particles are removed.
When installing the new foam, follow the manufacturer's instructions and safety guidelines. Typically, an expanding foam product designed for marine use is recommended. Apply the foam in a well-ventilated area, and ensure proper ventilation during the curing process. Allow the foam to cure completely before proceeding with any further steps.
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Replacing the plumbing
To replace the plumbing, you will need to remove the old lines and wires and install new ones. You should also take the opportunity to replace the fuel gauge sender and the wiring. It is also a good idea to perform a leak test on the new tank. To do this, pressurise the tank to three psi (or as per manufacturer instructions), then apply soapy water to all the connections. Each connection should then be carefully inspected for the presence of bubbles, indicating a leak. If any leaks are found, the connection should be re-seated, tightened and tested again.
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Leak testing the new tank
Before installing a new fuel tank in your boat, you should check whether the tank was foamed in place, a common boatbuilding procedure. If the tank was foamed in place and has leaked, the foam is likely to be saturated with fuel, which is hazardous. In this case, you'll need to remove the foam along with the tank. You should also replace the fuel gauge sender and the wiring while you have access to these normally inaccessible areas.
Once the new tank is in place, properly secured, and plumbed, you should perform a leak test. To do this, pressurise the tank to three psi (or as per the manufacturer's instructions) and apply soapy water to all the connections. Carefully inspect each connection for the presence of bubbles, which indicates a leak. If you find any leaks, the connection should be re-seated, tightened, and tested again.
While the connections are accessible, it's a good idea to replace old plumbing lines and wires. With the new tank in place, secured, plumbed, and leak-tested, you can repair or reassemble the boat's structure as necessary.
At the end of each boating season, it's recommended to leave the hatches open to allow the fuel tank compartment to dry out. If you smell fuel and suspect a leak, have the tank pulled, inspected, and repaired or replaced.
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Reassembling the boat
Once the new tank is in place, secured, plumbed, and leak-tested, the boat can be reassembled.
First, ensure that the tank is properly secured and that all connections are tight. Perform a leak test by pressurising the tank to three psi (or as per the manufacturer's instructions) and applying soapy water to all the connections. Carefully inspect each connection for the presence of bubbles, which would indicate a leak. If any leaks are found, re-seat and tighten the connection, then test again.
While the connections are accessible, it is recommended to replace old plumbing lines and wires. This includes the plumbing running to and from the engine(s), as well as to the fuel fill and vent. The fuel gauge sender and wiring should also be replaced.
If the tank was foamed in place, the foam is likely saturated with fuel and should be removed along with the tank. Smaller boats often have aluminium fuel tanks that are foamed in place under the deck.
Finally, repair or reassemble the boat's structure as necessary.
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Frequently asked questions
If your boat's fuel tank is old and at risk of leaking, it should be replaced. If you smell fuel and the hoses and fuel sender look OK, have the tank pulled, inspected, and repaired or replaced.
If the tank was foamed in place and has leaked, the foam is likely to be saturated with fuel, which makes it hazardous. You'll need to remove the foam along with the tank.
It makes sense to replace the plumbing running to and from the engine(s) and the fuel fill and vent, as these lines are probably as old as the tank. The same goes for the fuel gauge sender and the wiring.
After the tank is in place, plumbed, and deemed ready for use, a leak test should be performed. Pressurise the tank to three psi (or as per manufacturer instructions), then apply soapy water to all the connections. Each connection should then be carefully inspected for the presence of bubbles, indicating a leak. If any leaks are found, the connection should be re-seated, tightened and tested again.
Most installers glue the insulator to the tank, typically with 3M 5200 polyurethane adhesive/sealer or something similar.
