Looking for "tips" on replacing the OEM fuel tank in my 1999 Seafarer. I have a fabricator for the replacement tank which will be build based off of the original GW drawing and specs. I anticipate the most significant challenge will be the replacement of the fill hose, specifically at the upper clamping point. The access hole beside the starboard fish box is tight. Hopefully there will be no issues under the tank. Any previous experiences will be greatly appreciated.
Decided that this is the year to replace my 25 yo fuel tanks. No leaks. I plan to keep the boat. I'll document the process here.
Pulled the hatch. This hatch was rebuilt a few years ago with Coosa board. Looks good and feels solid. Hatch was set with 3M 4000 - kept everything sealed. Some difficulty cutting with blade to get it up. Not sure what it will go down with. Deck ports were caulked in from the underside as well. Kept the tanks dry.
I also put plastic over the fill, sending unit and pickup. This deflects any water away from the busy area of the tank.
There is no good way to work on the fuel fills. I cut a 12" square out on the flat part (flat to make repair easier). Replace all the hoses and install a new Perko fuel fill with bushing (included with new fill) to deflect water away from the fill.
On the Islander the forward tank was difficult to remove. There was a bulkhead that had to be cutout. After that the tanks was too long to tilt out so the face of the step had to be cut. Same deal...cuts on flat surface.
Repair was easy. Installed wood backing in corners with West 610 epoxy (tube). Make sure surfaces are clamped flat. Fill gap with more 610 but keep finished surface clean. Use AwlFair epoxy fairing to fill.
