As part of my rehab of the boat, I was planning to replace the fuel tank before repowering with new diesels.  We cut the deck out and began by cutting the top off the tank.  What we found was the the existing tank was in really good condition. Never expected that.  There was no softness anywhere and I cleaned it w acetone 3 times today.  We are going to leave it in place and glass all the parts back in.  

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Cut out the water tank

Cut out the cockpit floor and Joe Mello removing the fuel tank.


When the tank was taken out, it had been foamed in and had to remove that.  Took a while.  But worked out pretty well.

Tanks space cleaned out.  

Added the supports for the new tank, which I'm picking up tomorrow! It is 78" long and 230 gal.  The original fbgl tank was labeled 185 gals.  The new alum tank of same size from Luther's was 194 gal.  I opted for adding 11" and getting a little more capacity.  Still need to add the 40 gal water tank.  

This is the template I made to give to Bud Luther. Sitting on mahogany blocks which are under the baffles and  are coated w resin and epoxied to the floor. Luther is giving me a plastic strip to 5200 to the tank where it sits on the blocks.  I decided to make the sides plum to avoid any possible conflicts with the new motors.  Luther already had a drawing for a tank he made for Bill Johnson's boat and we worked with that.  

Jeff, I've posted some pics of the project tonight but for some reason couldn't upload the rest.    To your question about the bilge paint.  I used Interlux Bilgekote and mixed the grey and white.  It's pretty nice and rock hard. Highly recommend.  Added an extra coat under the tank area.  I really don't think you can replace the tank effectively without removing the cockpit floor.  It's absolutely not a big deal for the fiberglass guy who I'm working with.  But the results in the bilge are pretty stunning.  Happy to talk sometime.

Jeff said:

I have my motors out and I have spoke with the fab shop in RI I believe it is Luther's for a new fuel tank. Can I ask you what you painted your bilge with and possibly some pictures of how where you cut your deck for the removal. I'm still alittle bit hesitant to cut if up uhhg.

pic of painted bilge


The fiberglass guy I work with did the cutting.  We talked about going through the fish boxes but opted to for outboard of that to not have to deal with the fish box lips.  He will put the floor back in about a month.  Can send you more when that happens.  But getting access to the whole bilge area was great for my project. Installing the tank and all fuel lines, vents, exhaust/mufflers etc in the coming weeks.  Stay tuned!

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