Replace Fuel Tanks on Express 360

[sluggoe]

Hi All: Does anyone have experience replacing fuel tanks on a 2007 360 Express? I am aiming to get the job done by a large, respectable yard who has general knowledge (not specifically on grady boats). They said ~$12-$15K knowing that "they might find other stuff". Grady guys in NC said should not be too difficult because of the "cut-away" in the cockpit -- so the yard won't have to tear apart the deck and can re-calk after removing the rectangular deck portion that hides the tanks. My previous 282 had the same cut-away rectangle in the cockpit. Has anybody done this job (doesn't necessarily need to be a 360 but other models) themselves or had it done by a yard or Grady dealer??

My local Grady dealer is hesitant to do this job but maybe possible to twist their arm. Grady team in NC said there is a piece of fiberglass between the 2 tanks under the deck (tanks are 190 & 180 gal) that has to be removed and "re-glassed" but not sure how involved that is. Any insight / help would be appreciated b4 i undertake this process. Note that the yard wants to buy the tanks themselves (there is a place in Florida that has the exact tanks that i can order myself) but i guess they want the mark-up full profits on the job.

 

[fordfisherman]

Guesstimating tanks and hoses will run about 5k for those sizes plus freight. You may be better served having a local fab place make them. Call Grady customer service, they will provide specs on the tanks. It’s not a hard job if you have help and someone with experience. Could save some $$ with some leg work. Good luck.

 

[Ekea]

i did the tank on my Chase. at 205 gallons, it was somewhere around $4k. it was overbuilt at 1/4" wall thickness and extra internal baffles. i also ran new fill and vent lines. all in, i was under $5k total including all materials (i used unique and expensive hardware). If you have the means to physically lift the tanks out of the boat and over the gunnel, its not a bad job. the worst was running the new fill and vent lines, mine are internal to the gunnel, then turn 90 degrees, a run through the stringers to the tank cavity. i did have to cut a small hole where the 90 bend was, but i was able to do it behind another panel, so it wasnt a big deal. i think that i wouldnt need to cut the hole if i were to do it again.

 

[Halfhitch]

Any insight / help would be appreciated b4 i undertake this process. Note that the yard wants to buy the tanks themselves (there is a place in Florida that has the exact tanks that i can order myself) but i guess they want the mark-up full profits on the job.

First of all, I would not give the job to a dealer that is hesitant and doesn't really want to get into it. That means, they have little experience and are not good at it. Probably had a bad experience in the past with a customer. Go with a company that does that job regularly as a normal part of their business, even if it means taking your boat to them. There is nothing worse for you getting a good nights sleep than getting your boat back and having misgivings about what's below deck. It never goes away. If the contractor wants to provide the tanks, then sit down with them and go over the specs of their tank compared with the one you would like to have built and decide which is the best value. A few hundred bucks one way or the other for those tanks is unimportant. What is most important is you get good quality aluminum and proper welding and testing. A company that does that job as a regular part of their business can dial you in on what's important and will probably bring up important points that you or I hadn't thought of.

Also, I would ask if they would provide progress pictures as they do the job for your piece of mind.

 

[Hookup1]

Attached is a thread I documented replacing the tanks in my 1997 268 Islander. Your hull will have different challenges. You should talk to another GW owner who has experience with your hull. When I talk to any contractor working on my boat, car, truck, home, etc. I have a simple test: "Do I know more about the problem than the guy I'm talking to?". Many fail - find someone else. Read my thread thru and you will understand the challenges and choices you should be hearing about when you have your talk.

Key things to consider are bulkheads that have to be removed and re-glassed to get tanks out. Same with cutting decks or other glass areas for access. You may or may not have this issue with your hull.

Tanks should be from USCG certified tank builder not "some guy I know that welds aluminum". The insulation strip material and how it's installed is important too.

Replace all the hoses and maybe fuel fills.

SP Tanks in Clermont, NJ for tanks. They build tanks for many of the custom boat builders. GW went all the way to Florida for their tanks.

Thread '268 Islander Fuel Tank Replacement'

Jul 10, 2023

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.

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• Hookup1
• Replies: 70
• Forum: Tips, Modifications and Electronics

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