Hi all haven’t been on the site for a while but figured I’d post some info on a fuel tank replacement.The past 2 times I’ve used the boat after having the tank topped off I noticed strong gas smell coming from the interior of the console and even had some gas / water mix pump out through the bilge while fishing offshore.I chalked the first time up on the guys at the dry stack maybe overfilling or putting a gallon down a rod holder.
I examined everything I could access hoses, sender and limited amount of the tank I could see with no obvious problems. My mechanic did the same thing and he concluded only way to be 100 percent safe was to remove the tank and examine / replace.The deck was cut and tank removed last week revealing a small hole near the top of the tank. I didn’t see it as tank was sent ou to a fabrication shop to be used as a template for the new tank.
I guess better safe than burning alive offshore 20 miles.the good news is the tank wasn’t foamed in and was removed easily. The new tank will be epoxy coated with all new fuel lines and hopefully be done in 3 weeks.The bad news is the 180 gallons of fuel that had to be pumped out on my dime prior to the tank removal and the estimated 6k price tag.I didn’t find much info searching about a tank replacement on a sailfish so figured I’d share.
Awesome, thanks for the info and glad you caught it! I have an '08 2860...fuel tank replacement is one of those nagging worries I've had knowing I plan to keep the boat for awhile.
Do you have any pics you could share of the process? I toured the factory once and Denny showed me where they had molded in a line to cut the deck when needed...I'll be curious to hear how solid it is once the deck is glassed back in.
I'd also be tempted to re-rig whatever I could when the deck is wide open.
I went to get pictures but it’s up high on a rack and the marina was busy but will post pics if I get them.Also having the throttle and shift cables done while it’s opened up.
Apparently where the deck was cut will not be noticeable according to the shop after it’s glassed back in.I’ll def get pictures of the finished product posted up when ever that maybe. I may consider selling it when done figuring this should add value.
A little off topic but what do you all think a good listing price would be? 1700 hours on yam 150s overall in good shape , no trailer?
As an alternative to doing destructive removal of the tank to look for a sign of a leak, they can also be pressure tested. Not that it would've changed your outcome but for anyone else they may have concerns about the integrity of their tanks
Good point about the pressure test! Forgot that part . the mechanic said sometimes tanks will pass a pressure test then can soon develop a leak.He showed me another tank from a different boat they had pulled out.This particular aluminum tank had white corrosion spots in the metal which he rubbed with a set of pliers knocking the corrosion off then easily pushed a hole into the tank.
Since in my situation there was gas in the bilge and the age of it I opted for replacement . in retrospect I could have continued running it for awhile on say half a tank and prolly been fine but didn’t want to risk it and couldn’t sell it in that condition.I ran lots of scenarios through my mind like bad fill or vent hoses leaking through the sender etc.. trying to avoid this. It really freaked me out when gas started pumping out through the bilge offshore with the family.
I’ve read some postings on the hull truth that when test driving a boat you should do so on a full tank as this is usually when they will first show signs of a leak.
Reading all the post you made the wise and safe choice. The Captain must always look out for the safety of the crew. But it sucks to have to drop that kind of coin into it. I’m glad you shared the price to replace. I’ve heard other ridiculous prices of 15-20k to change a tank which was hard to believe. She’ll be good as new when you get her back.
Post by jupiter2360 on Apr 14, 2021 9:18:59 GMT -5
Is there any chance you could post a few good pics showing the cut lines and opened up as found conditions below deck, as well as empty condition as found when tank is removed. I feel for you as I have done 2 tanks in Makos before. I recommend 3/16 or 0.192 plate thickness which is standard over 125 gal. Also properly applied coal tar epoxy coating is highly recommended. My 2006 2360 has a poly 153 gallon tank and was an important factor in my purchase of my older used rig.
I am very curious how tank was supported below deck and what materials where in direct contact with the aluminum and if any 2-part foam was used to brace or secure tank.
Sorry no pics yet a home Reno project has taken up all my time.unfortunately I never saw the old tank it was sent out to the shop who is rebuilding it. About 2 months into this project at this point. it took 5 weeks for the mechanic to get the tank ( only a few actual hours work) out now it’s been about that long waiting for the new tank to be built.Gotta love the marine industry that charges a premium for such slow service.
From what I was told by the mechanic the old tank had tabs on it screwed to the stringers and it wasn’t foamed in.I’m not sure of any other details until I see it.
So fast forward to today 6/3 ,four months ago I authorized the work to be done at my marina. the new tank and all new fuel lines are installed and am awaiting the deck to be glassed in and the leaning post reattached .hopefully done in the next week or so.
The deck was cut along the lines in the floor that are smooth without non skid apparently sailfish planned well in advance for this repair .I will try to attach the only pic I have.I never got to see the original tank or how the new tank is installed under the deck.
A quick synopsis:
5 weeks for tank to be removed and sent to outside vendor to measure and replicate new tank .
Two months for vendor to build and epoxy coat the new tank and send back to my marina.Apparently this vendor builds for a major boat manufacturer so I’m guessing my small job got pushed to the side.
One month delay my marinas forklifts have been non operational leaving hundreds of customers without being able to use their boats ( A whole other story) .My boat was on a upper rack.
New throttle and shift cables are also being installed.When I originally posted I hoped to have a better thread with pics but my marina and their vendor made timing for me getting pics very difficult and frustrating overall to put it politely.
Unfortunately not allowing you to take photos raises the question of how honest they were with you. I'm sure covid also played a part in the delays, seems to be the new excuse for everything these days.
Looks like my 2002 236 is due as well I called Sailfish, they only had records back for a 2004 236 and the tank manufacturer (still around and in Florida). He said that was a 130 gallon. My literature says 125 on the ‘02
They also had no info to offer on the cutting.
He said he thought the helm has to come off (unless that tank is a funky design with some sort of extended step down, it doesn’t appear so). Looks like the leaning post for sure.
I contacted the manufacturer. We shall see
I found a glass guy who has done quite a few. Hopefully the tank doesn’t tank months (I suspect it will though)
Last Edit: Jun 11, 2021 8:55:24 GMT -5 by Ol Mucky
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