Fuel fill hose replacement.

Osprey1952

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I am looking to replace the fuel fill hose and vent hose on my 1999 Adventure. Not leaking but the fuel hose is very hard so I think it’s time. Anyone here ever do this. I can see from the deck plate opening above where they connect to the tank that the hose goes through a stringer and then under the fish box before going up to the gunnel. Is this one hose that just bends to go from horizontal to vertical at the gunnel? Looks like 1 1/2” fuel, not sure of the size of the vent line.
 

DennisG01

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The fill hose is supposed to be hard - it is wire (metal) reinforced. Unless it's cracking excessively, I wouldn't worry about it. Yes, it will be one length of hose. Vent line should be 5/8".

With that said, it's the original, it's over 20 years old and it would't be a bad idea to do it.
 
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wrxhoon

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What Dennis said, I would change it if it was cracked. If the boat lived up north in sub zero C temps ( sub 32F) it could become fragile with time.
 
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leeccoll

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Osprey,
What Dennis and wrxhoon said is spot on, I am only going to add that replacing the main and vent lines is a major deal for most. You will need to cut open your deck hatch to attach the new lines. That's at a minimum. I had to cut out extra access to get the old main hose out during my project last summer. If I could add any advice forward it would be to wait and replace the lines and your fuel tank at the same time. Eventually all will need to be addressed, it seems to be a good idea from an efficiency point of view to do them at the same time, unless your hose is leaking. Attaching my 1986 hose. Looks awful, yet it wasn't leaking yet~
10.jpg
 
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wrxhoon

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Wow, that's one terrible looking hose there!! My old boat was 12 years younger than yours but the fuel hose looked like new when I sold her.
 

leeccoll

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Wow, that's one terrible looking hose there!! My old boat was 12 years younger than yours but the fuel hose looked like new when I sold her.
That section was under the fishbox, the outer skin probably cracked as I was pulling it around the bend there. The hose sections at the gunnel and fuel tank looked acceptable. Better quality hoses can really hold up internally it seems.
 
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DennisG01

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I've said it before, and I still don;t know why, but my '93 has a spare fill hose taped to the original, from the fill to the tank. Yes, it's old, but it has never had fuel in it.
Do you have a single fuel tank... and could your boat have had the option for dual tanks?
 
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VeroWing

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I've changed fill and vent hoses on a couple mid/late '80s Gradys, and you would be surprised how bad those hoses get under those decks. Should always sniff around under hatches, etc after fueling older boats. Best way I've found to install new hoses is to attach them end to end to old hose and pull it through while pulling old hose out. Of course you have to remove tank cover(s) and make sure hole where hose enters tank compartment is opened up enough to slide hoses through. My current boat, 1989 Gulfstream was more difficult because hose was so deteriorated, and I ended up cutting out a larger hole around where hose entered tank compartment to get new hose in place. Afterwards I glass in removed piece using epoxy resin.
 
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seasick

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I haven't done it but based on my inspection, you probably can replace the fuel fill hose on a 208 without cutting any holes. You can see the hose through the inspection plate in front of the helm seat and you can see where the hose attaches to the combo fill fitting under the starboard gunnel. If you look closely you will probably also see a spot or two where the hose is tie wrapped. I think that the method that works is to couple the new hose to the old at tank and push it from the tank side while pulling from the fill side or the deck plats by the seat. I suspect that you may need/want to unscrew the full fill fitting to make it easier o unclamp the hoses as well as pull the hose through the cutout.

Let us know ho it works out
 
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Osprey1952

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1999 Adventure 208. only one tank for the model, came from the factory with the poly tank.
 

GW VOYAGER

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I have changed mine on a 1996 voyager . The main tank hose and vent hose went fairly well but the auxiliary tank was another story altogether.. Had to cut an access hole in front of captain chair. The O.D. Of the new vent hose was slightly larger than the original and wouldn’t fit through the factory drilled hole. PIA but can be done..
 
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