Fuel Tank Replacement 1986 204C

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gxsess

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So I had my boat out for the first time this season and I believe I have a leak in the aluminum fuel tank. I changed out all the lines in the offseason since I had a bad fill pipe. Had pretty nasty gas smell in the cabin after about an hour or so of fishing, I pulled out of the ramp, pretty steep angle, and the bilge shot a pretty nasty gas water mix out.

In any event, I am changing the tank. When I was in there doing the new lines, it looked like the original tank was packed in there pretty tight.

Curious is anyone has done this, and if there is anything that I should be on the lookout for, or anything that is going to make it particulary difficult to pull this thing out and get the new one in. I think I am going to go with a polyethelyne tank, I am assuming its going to be lighter, and I wont have to concerned with a weld going bad like I would with an aluminum. really dont want to pull up that deckplate again for a long time. twice in a month is enough for me.
 
i will be interested to see the responses you get. I have an '88 204c and as far as I know the tank is in good shape, but you never know.

FYI - when I had some questions about the tank for a new fuel sender I contacted Grady White. They sent me copies of the shop drawings for the original tank. I believe the company that made the original is still in business and can build a replacement to fit.

Also do a search on this site. I seem to recall a couple of people that have tackled this project before.

Good luck.
 
I changed both tanks in my 24 offshore 2 years ago. They both developed leaks where the tanks sat on rubber pads. The rear tank (aux) gave up first. The main tank (front) was about to start leaking.
In my opinion....the salt water and the aluminum combined with the rubber eat through the tanks.
I had the front one re-lined by a local compnay here in Mpls, and I bought the aux. from the company in Flordia that makes tanks for Grady.
I set the tanks using spray in place urethane insulatin and have had no issues.
The tank filler hoses in the ole 1989 offshore were also both shot and needed replacing.
If the tank is not real bad I'd say the gas tank reliner in good optyion. The stuff they put in it and on it is like rubber and I got a 15 year warranty


Good luck in what you decide.,
 
Been here, done this. I had to take out 2 inches of deck at the stern to get the tank out. Check my posts. If you don't see what you need there pm me.
 
you were right, had to take 2 inches out of the deck. its almost like they made the boat around the tank. Everything s fine now, hope I never have to lift that deckplate again
 
Filler hose replacement 88 204c

I need to replace the fuel filler hose, how does one access the nuts on the fuel deck plate. It connects to the filler hose in between the two transom walls.
 
Look at the label on the tank from the manufacturer. He is located in FL and will ship you an exact replacement for your boat. I helped replace both tanks on a 1980 Offshore with OEM stuff. The job went very well. Grady provided some engineering drawings regarding getting the tanks/hoses out and back in. Good Luck.
 
Stay with aluminum, need no such concerns on welds.
Stay with same size. Get all new hoses, specify WEMA for level senders.

Grady layed in tanks and everything esle down there before liner was mated to hull.
 
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