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Author Topic:   sealing fuel tank cavity

efjr1 posted 03-22-2009 04:45 PM ET (US)
I own a 1986 18 foot outrage and want to reseal the entire fuel tank cavity. Should I use marine silicone , 4200 or 5200? Thanks for any insight.
DeeVee posted 03-22-2009 09:34 PM ET (US)
Do not use 4200 or 5200 at the fuel tank cover seams. These products are classified as adhesive sealants, with emphasis on the "adhesive" part, especially for the 5200. If you never want to take something apart, use 5200. 4200 is the same as 5200, except not as strong.
The fuel tank cover is made to be removable so you can service the fuel tank if needed. I believe different caulkings have been used by the manufacturer over the years, with at least one of them being a silicone based product.
Sue Lodell at Twin Cities Marine carries a product that works well and matches the gelcoat nicely. I am sorry that I don't remember the name of the product.
Others may chime in with more knowledge.
Doug
Jeff posted 03-22-2009 10:48 PM ET (US)
When I resealed my deck on my 22 Outrage I used Boat Life flexible marine polysulfide chalk. It is a sealant and not a glue. Which is what you want. Also this sealant has great flexible properties that allows it to have a long crack free life.
http://boatlife.ipower.com/shop/index.php?main_page=index&cPath=2_12
I went with the white and after first year of use the white weathered to a near match of the desert tan.
Just and FYI. Before you lay your sealant in run a 40lbs test fishing line in the joint and chalk over it leaving one end with extra hanging out. Usually the extra can sit in the rigging tunnel. Then if you ever have to pull the deck up you just grab the end and pull the line up thus cutting the chalk and allowing the deck to release.
efjr1 posted 03-23-2009 09:26 AM ET (US)
Thanks for the replies. I will use the silicone and the idea of the 40 weight fishing line is a good one.
Tom W Clark posted 03-23-2009 11:50 AM ET (US)
Silicone, polyurethane and polysulfide caulks have all been used and can be used to seal the seam around the fuel tank cover.
I would not use 3M 5200 but I would use 3M 4200 if I had to use a polyurethane.
The clear silicone that Whaler used on my 1983 Outrage 18 would *not* peel off the hull. I would not use silicone.
I think Jeff's recommendation of a good polysulfide caulk is the best, especially if you can get a good color match.

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Author	Topic: sealing fuel tank cavity
efjr1	posted 03-22-2009 04:45 PM ET (US) I own a 1986 18 foot outrage and want to reseal the entire fuel tank cavity. Should I use marine silicone , 4200 or 5200? Thanks for any insight.
DeeVee	posted 03-22-2009 09:34 PM ET (US) Do not use 4200 or 5200 at the fuel tank cover seams. These products are classified as adhesive sealants, with emphasis on the "adhesive" part, especially for the 5200. If you never want to take something apart, use 5200. 4200 is the same as 5200, except not as strong. The fuel tank cover is made to be removable so you can service the fuel tank if needed. I believe different caulkings have been used by the manufacturer over the years, with at least one of them being a silicone based product. Sue Lodell at Twin Cities Marine carries a product that works well and matches the gelcoat nicely. I am sorry that I don't remember the name of the product. Others may chime in with more knowledge. Doug
Jeff	posted 03-22-2009 10:48 PM ET (US) When I resealed my deck on my 22 Outrage I used Boat Life flexible marine polysulfide chalk. It is a sealant and not a glue. Which is what you want. Also this sealant has great flexible properties that allows it to have a long crack free life. http://boatlife.ipower.com/shop/index.php?main_page=index&cPath=2_12 I went with the white and after first year of use the white weathered to a near match of the desert tan. Just and FYI. Before you lay your sealant in run a 40lbs test fishing line in the joint and chalk over it leaving one end with extra hanging out. Usually the extra can sit in the rigging tunnel. Then if you ever have to pull the deck up you just grab the end and pull the line up thus cutting the chalk and allowing the deck to release.
efjr1	posted 03-23-2009 09:26 AM ET (US) Thanks for the replies. I will use the silicone and the idea of the 40 weight fishing line is a good one.
Tom W Clark	posted 03-23-2009 11:50 AM ET (US) Silicone, polyurethane and polysulfide caulks have all been used and can be used to seal the seam around the fuel tank cover. I would not use 3M 5200 but I would use 3M 4200 if I had to use a polyurethane. The clear silicone that Whaler used on my 1983 Outrage 18 would not peel off the hull. I would not use silicone. I think Jeff's recommendation of a good polysulfide caulk is the best, especially if you can get a good color match.