Replacing fuel tank 1988 Overnighter 204c

[evram10]

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.

 

[Hookup1]

I'm not familiar with your hull. I have a 1997 268 Islander that I did fuel tanks on a few years ago. At 37 years old I would say you need a new tank. I just had my transom replaced due to water intrusion. You won't know about stringers until you get in there but transoms are generally more of a problem. Poly tank is a good idea. If you get an aluminum tank use a USCG certified tank builder. Make sure it's properly insulated and mounted.

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
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• Forum: Tips, Modifications and Electronics

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