Replacing fuel tank 1988 Overnighter 204c

evram10

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Joined
Jul 28, 2026
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Age
25
Model
Overnighter
Hello,
I recently purchased a 1988 Overnighter 20' and upon filling the tank quickly discovered that there is a sizable fuel leak despite being told by the seller there was not and not finding any gas in the bilge upon initial inspection. From what I can see of the lines and fuel water separator I believe that the leak has to be coming from the tank, which is the original aluminum tank. Luckily this model has a deck hatch cutout so I don't think it will be too intense of a project to open that hatch and remove the tank. Just wondering if anyone has done this or has any tips on how to make this process easier or different ways to go about it. A local marine welding shop has quoted me $1300 for a new aluminum duplicate, but I am also debating going with a smaller poly tank. I also suspect I will find some rot when I open the hatch so if anyone has any tips on the threshold for replacing/repairing stringers that would be helpful as well. I believe I got the boat for a good deal as its coming with a 2017 Yamaha 150 with low hours which is primarily why I bought it and I'm not looking to get into any structural repairs/work on the hull. Thanks.