Replacing The Fuel Tank In Your Black Jack Boat

Replacing the fuel tank of a BlackJack boat can be a challenging task. While there are no specific instructions available for the BlackJack boat, the process typically involves assessing the condition of the tank, identifying any leaks or cracks, and determining the appropriate replacement option. The complexity of the replacement process may vary depending on the accessibility of the fuel tank and the specific model of the BlackJack boat. It is recommended to consult a professional or refer to detailed instructions provided by boat manufacturers or specialized forums to ensure a safe and effective fuel tank replacement.

Removing the fuel tank

Before beginning, ensure you have the necessary tools and safety equipment, such as gloves and eye protection, and that you are working in a well-ventilated area. It is also important to relieve any pressure in the fuel system before proceeding. Refer to your boat's manual for specific instructions.

Start by locating the fuel tank. On the BlackJack boat, the fuel tank is typically located in the forward bilge sump. Once you have accessed the fuel tank, the next step is to disconnect the fuel lines, hoses, clamps, and any other components that are attached to the tank. Be careful to catch any remaining fuel in a suitable container and properly dispose of it later.

After disconnecting the fuel lines, you will need to remove the mounting hardware that secures the fuel tank in place. This may include bolts, brackets, or straps. Carefully remove these fasteners, making sure not to drop them into the bilge. You may need to loosen or remove surrounding components to access the mounting hardware.

With the fuel lines disconnected and the mounting hardware removed, you should now be able to lift the fuel tank out of its compartment. Depending on the size and weight of the tank, you may need assistance to safely lift and manoeuvre it out. Place the old fuel tank in a safe area, away from any ignition sources.

At this point, it is crucial to inspect the area where the fuel tank was located for any signs of damage, corrosion, or leaks. Look for cracks, holes, or discolouration that could indicate a problem. If you notice any issues, address them before installing the new fuel tank. Ensure the compartment is clean, dry, and free of debris.

Finally, refer to the instructions provided by the manufacturer of the new fuel tank for proper installation procedures. Pay close attention to any specific guidelines to ensure a safe and correct installation. This may include the use of gaskets, seals, or other components to prevent leaks and ensure the tank is securely mounted.

Cleaning the fuel tank

While it is not entirely clear what a "Black Blackjack" is, I did find some information on how to clean a fuel tank.

Cleaning a fuel tank can be a challenging task, especially when dealing with stubborn residues like black tar or asphaltene, which can result from diesel fuel breaking down into its original state. This process is common in certain types of engines, such as the 60 Series Detroit.

One method for cleaning a fuel tank involves using a combination of chemicals and custom-bent lines to steam clean the inside of the tank. This approach was developed by cleaning experts and may be effective in removing the black residue that has proven resistant to other methods such as steaming, bleach, parts cleaning solvent, soaps, and liquid cleaners.

In some cases, it may be necessary to remove fuel tanks for cleaning. The labour cost associated with this process is typically around $1200.

If you are dealing with black tar or sludge in your fuel tank, there are a few things you can try. One suggestion is to drain the tank, hand wipe as much of the gooey substance as possible, and then use gasoline to clean the rest. Let the gasoline sit in the tank for a day, then drain it and let the tank air dry for several days. During this process, you can also spray gasoline inside the tank using a pump-up garden sprayer to ensure that all the sludge is removed.

Another approach to cleaning the fuel tank is to use additives and change the filters frequently. This method may not completely fix the problem, but it can help improve the performance of your vehicle. Running lots of additives can help break down the sludge and improve fuel flow. Changing the filters regularly will also prevent the build-up of contaminants and ensure that your vehicle runs more smoothly.

If the fuel tank is difficult to access or clean, replacing it may be the best option. This can be a costly endeavour, but it may be more feasible than spending extensive time and resources on cleaning the existing tank.

Repairing cracks and leaks

If you suspect that your fuel tank has a crack or a leak, there are several steps you can take to identify and address the issue. Firstly, check the hoses, clamps, and filter for any signs of cracks or leaks. If you don't find any issues there, you may need to perform a pressure test on the tank to identify potential leaks. Be cautious when pressurising a gasoline tank, as it can be dangerous. You can seal the vent and fill tubes and pressure up the tank to 3 psi to see if it holds. Alternatively, you can use a lower pressure of around 1 psi and use nitrogen instead of gasoline to be safer.

If you have a plastic tank, it is common for fuel vapours to permeate through. In this case, you may want to consider replacing the tank with a newer EPA-certified, triple-wall, and low-permeation tank. You can also try to identify any loose screws that may be causing a poor seal between the tank and the black fuel pickup piece. Ensure that all hose clamps attached to the black piece are tightened.

If you suspect that your fuel tank has a crack or leak, it is important to address the issue as soon as possible. Fuel vapours can be dangerous, especially inside the hull of a boat. If you are unable to identify the source of the problem, it is recommended to seek professional help. Take your boat to a marine shop or auto shop that has experience with fuel systems and gas detection sniffers to pinpoint the exact location of the leak.

In some cases, the black coating or sludge inside your fuel tank may be due to diesel fuel turning back into its original state, asphalt, or the presence of algae. Cleaning this sludge can be challenging, and you may need to seek professional help or consider replacing the tank altogether.

Replacing the fuel tank

The first step is to identify the type of fuel tank you have. Most marine tanks are built from aluminum. Stainless steel is sometimes used, but it is harder and more expensive. Permanent polyurethane or plastic replacement tanks are additional options for both gas and diesel applications. If you have a fiberglass fuel tank, it is likely becoming problematic due to ethanol-enhanced gasoline, which breaks down the resin in the fiberglass. In this case, the only viable solution is to replace the tank.

Once you have identified the type of fuel tank you have, you can begin the process of removal and replacement. If your boat has accessible compartments, such as a deck seam around the console, removing the old tank and installing the new one will be easier. On boats without easy access, you may need to cut the deck to remove the old tank. This will require reglassing the deck after the new tank is installed.

If your boat has internal flotation foam in the hull, be careful when removing the old tank as leaked gas can soak into the foam. Hand tools should be used to remove the foam, as power tools could create a spark.

When installing the new fuel tank, be sure to follow the manufacturer's instructions carefully. Failure to do so could result in a safety hazard or shortened tank life. Pay close attention to the tank's construction materials and thickness, grounding, venting, pressure checks, load distribution, and insulation. These are all important factors in ensuring the safe and proper installation of your new fuel tank.

Replacing a fuel tank can be a labor-intensive and costly process, but it is necessary to ensure the safety and longevity of your boat. By choosing the right type of tank and following the proper installation procedures, you can prolong the life of your boat and enjoy many more seasons on the water.

Preventing future problems

Regular Maintenance: Establish a routine maintenance schedule for your fuel tank and stick to it. This should include regular inspections for leaks, cracks, or corrosion, especially if your tank is made of aluminium or fiberglass. Check hoses, clamps, and filters for any signs of deterioration and replace them as necessary.

Proper Installation: Ensure your fuel tank is installed correctly by a qualified professional. Improper installation can lead to leaks and other issues. Consider coating the outside of aluminium tanks with epoxy to provide extra protection against corrosion.

Fuel Type: Be mindful of the type of fuel you use, especially if you have an older model. For example, ethanol-enhanced gasoline can break down the resin in fiberglass tanks, leading to clogged fuel injectors and overloaded filters. Using the correct fuel type for your engine can help prevent these issues.

Tank Materials: When replacing a fuel tank, consider using modern materials such as rotationally molded polyurethane tanks, which offer advantages like corrosion resistance and durability. Stainless steel is another option, although it may be limited due to cost and the hardness of the metal.

Custom Builds: If you're replacing a fuel tank, consider a custom build to fit your specific requirements. Companies like Atlantic Coastal Welding offer custom tank builds along with detailed installation instructions if you decide to take on the project yourself.

Safety First: Always prioritise safety when working with fuel tanks. Follow instructions carefully, whether you're performing maintenance or installing a new tank. Fuel vapors can be dangerous, so ensure proper ventilation and avoid potential spark sources, especially when working in enclosed spaces.

Frequently asked questions