OUTRAGE V-20 Fuel Tank: Replace or Sell Boat

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Author Topic:   OUTRAGE V-20 Fuel Tank: Replace or Sell Boat

topsaildoc posted 03-19-2012 04:06 PM ET (US)
[I]'m having some [problems or concerns] with my 1981 OUTRAGE V-20. [I] think the aluminum [fuel] tank is leaking. Water [appears in] the [gasoline] when it rains. The last time [the fuel tank was] over-filled [gasoline] ended up in the bilge. [I]s there even a [replacement fuel] tank available for this old [1981 Boston Whaler OUTRAGE V-20]? [W]here can [I] get [a replacement fuel tank for a Boston Whaler OUTRAGE V-20]? About how much should [I] expect to pay [for a replacement fuel tank for a Boston Whaler OUTRAGE V-20]? [M]aybe [I] should just sell [my Boston Whaler OUTRAGE V-20]. [T]hanks--todd
jimh posted 03-19-2012 07:03 PM ET (US)
Visit http://www.floridamarinetanks.com/
powdahbonz posted 03-19-2012 07:05 PM ET (US)
Step one would be to inspect your fuel filler hoses. Pull up your Beckson center and rear plates to inspect the rubber. Next, pressure test your tank. If at 3-PSI it's not resisting, you likely have a leak or perforation. I have just removed my deck plate from bow to stern and will be digging into my tank and cavity this weekend. Thirty years is a long time.. [I] hate to be a downer but either run [on-deck fuel] tanks--I did last season--or pull the tank. I'll be posting pics of my experience as I go along. Happy to talk with you about it. E=mail at jdbonz@msn.com and I'll give you my phone.-- Derek
jimh posted 03-19-2012 07:10 PM ET (US)
If you have not replaced the fuel filler hose from the fuel filler inlet to the fuel tank, that hose is probably the source of the leak.
powdahbonz posted 03-19-2012 07:13 PM ET (US)
I've received quotes from $800 to $1,100 (not including) shipping for aluminum and polyurethane [fuel tanks]. I love my boat, it's paid for, and, in order to sell it, I figure that the replacement of the tank is a [plus].
topsaildoc posted 03-19-2012 07:30 PM ET (US)
[T]hank you guys; [I]'ve already replaced the filler hose. [I] e-mailed [F]lorida [M]arine [T]anks. [I] didn't think of the on-deck fuel tank--what a good idea! [T]hanks again--todd
Hoosier posted 03-19-2012 08:32 PM ET (US)
Did you replace the line to the fuel vent? If you have spilled fuel in your bilge when you over filled that could be where it came from.
Binkster posted 03-19-2012 09:41 PM ET (US)
Years ago I had a leaking aluminum tank in a 24' Aquasport I owned. I removed the foamed in tank and saw that the front end had some corrosion. Filled it with water and saw the leak at the front bottom edge. I washed out the tank, emptied it, measured back about 6 inches, and with a straightedge drew a line around the tank with a black marker. I cut the end off with a circular saw and an aluminum blade. there was no other corrosion anywhere else. I then had a new aluminum end welded on. Lost about 5 gallons of space. Reinstalled the tank, end of problem.
rich
Buckda posted 03-20-2012 05:50 PM ET (US)
Replacement tanks are expensive, but all may not be lost - although it is still a very large job.
Once you have removed the tank, you will know what you have on your hands. Both of my tanks showed some pitting and surface corrosion on the exterior. I used a mechanic's boroscope and determined that there was virtually no corrosion inside the tanks....so I contracted with a local welder to make some minor repairs. None of my corrosion was through the tank and my tanks were NOT leaking.
I've sanded the tanks clean to bare metal and will be re-coating the tanks with a quality covering like Rhino-lining once they've satisfactorily passed a pressure test.
The whole project will cost significantly less than replacement, however, it is a TON of work, and the trade-off in price means I'll be inspecting the system for leaks much more frequently. I've made a modification to the hull to make this easier (a drain port through the stern bulkhead into the live-well) and to make it easy to introduce water/wash the area down and drain/dry it when stored on the trailer.
I believe that this is the biggest failure in Quality that Whaler made in the 1980's - foaming in the tanks definitely introduced a major headache for owners 30 years down the road...but then again...30 years is pretty darn good service for a component in a marine environment...so while it is a gripe, it's a relatively small one....
Hoosier posted 03-22-2012 03:32 PM ET (US)
One thing to consider, especially if you have the tank out of the boat, is having it professionally sealed. Radiator shops can apply a sealer that is also resistant to ethanol. You used to be able to get the stuff at auto stores but now it can only be professionally applied.
Buckda posted 03-22-2012 05:57 PM ET (US)
Heck, JB Weld says they're ethanol-proof. I have some old JB Weld in the toolbox. I may mix up a bit and set it in a jar with gasoline just to see.
Hoosier posted 03-26-2012 04:36 PM ET (US)
It's going to take a lot of JB Weld to seal those tanks. They put the stuff in and then roll it around to coat all the inside surfaces. The first tubes will have set up before you squeeze out the 100th. ;-)

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Author	Topic: OUTRAGE V-20 Fuel Tank: Replace or Sell Boat
topsaildoc	posted 03-19-2012 04:06 PM ET (US) [I]'m having some [problems or concerns] with my 1981 OUTRAGE V-20. [I] think the aluminum [fuel] tank is leaking. Water [appears in] the [gasoline] when it rains. The last time [the fuel tank was] over-filled [gasoline] ended up in the bilge. [I]s there even a [replacement fuel] tank available for this old [1981 Boston Whaler OUTRAGE V-20]? [W]here can [I] get [a replacement fuel tank for a Boston Whaler OUTRAGE V-20]? About how much should [I] expect to pay [for a replacement fuel tank for a Boston Whaler OUTRAGE V-20]? [M]aybe [I] should just sell [my Boston Whaler OUTRAGE V-20]. [T]hanks--todd
jimh	posted 03-19-2012 07:03 PM ET (US) Visit http://www.floridamarinetanks.com/
powdahbonz	posted 03-19-2012 07:05 PM ET (US) Step one would be to inspect your fuel filler hoses. Pull up your Beckson center and rear plates to inspect the rubber. Next, pressure test your tank. If at 3-PSI it's not resisting, you likely have a leak or perforation. I have just removed my deck plate from bow to stern and will be digging into my tank and cavity this weekend. Thirty years is a long time.. [I] hate to be a downer but either run [on-deck fuel] tanks--I did last season--or pull the tank. I'll be posting pics of my experience as I go along. Happy to talk with you about it. E=mail at jdbonz@msn.com and I'll give you my phone.-- Derek
jimh	posted 03-19-2012 07:10 PM ET (US) If you have not replaced the fuel filler hose from the fuel filler inlet to the fuel tank, that hose is probably the source of the leak.
powdahbonz	posted 03-19-2012 07:13 PM ET (US) I've received quotes from $800 to $1,100 (not including) shipping for aluminum and polyurethane [fuel tanks]. I love my boat, it's paid for, and, in order to sell it, I figure that the replacement of the tank is a [plus].
topsaildoc	posted 03-19-2012 07:30 PM ET (US) [T]hank you guys; [I]'ve already replaced the filler hose. [I] e-mailed [F]lorida [M]arine [T]anks. [I] didn't think of the on-deck fuel tank--what a good idea! [T]hanks again--todd
Hoosier	posted 03-19-2012 08:32 PM ET (US) Did you replace the line to the fuel vent? If you have spilled fuel in your bilge when you over filled that could be where it came from.
Binkster	posted 03-19-2012 09:41 PM ET (US) Years ago I had a leaking aluminum tank in a 24' Aquasport I owned. I removed the foamed in tank and saw that the front end had some corrosion. Filled it with water and saw the leak at the front bottom edge. I washed out the tank, emptied it, measured back about 6 inches, and with a straightedge drew a line around the tank with a black marker. I cut the end off with a circular saw and an aluminum blade. there was no other corrosion anywhere else. I then had a new aluminum end welded on. Lost about 5 gallons of space. Reinstalled the tank, end of problem. rich
Buckda	posted 03-20-2012 05:50 PM ET (US) Replacement tanks are expensive, but all may not be lost - although it is still a very large job. Once you have removed the tank, you will know what you have on your hands. Both of my tanks showed some pitting and surface corrosion on the exterior. I used a mechanic's boroscope and determined that there was virtually no corrosion inside the tanks....so I contracted with a local welder to make some minor repairs. None of my corrosion was through the tank and my tanks were NOT leaking. I've sanded the tanks clean to bare metal and will be re-coating the tanks with a quality covering like Rhino-lining once they've satisfactorily passed a pressure test. The whole project will cost significantly less than replacement, however, it is a TON of work, and the trade-off in price means I'll be inspecting the system for leaks much more frequently. I've made a modification to the hull to make this easier (a drain port through the stern bulkhead into the live-well) and to make it easy to introduce water/wash the area down and drain/dry it when stored on the trailer. I believe that this is the biggest failure in Quality that Whaler made in the 1980's - foaming in the tanks definitely introduced a major headache for owners 30 years down the road...but then again...30 years is pretty darn good service for a component in a marine environment...so while it is a gripe, it's a relatively small one....
Hoosier	posted 03-22-2012 03:32 PM ET (US) One thing to consider, especially if you have the tank out of the boat, is having it professionally sealed. Radiator shops can apply a sealer that is also resistant to ethanol. You used to be able to get the stuff at auto stores but now it can only be professionally applied.
Buckda	posted 03-22-2012 05:57 PM ET (US) Heck, JB Weld says they're ethanol-proof. I have some old JB Weld in the toolbox. I may mix up a bit and set it in a jar with gasoline just to see.
Hoosier	posted 03-26-2012 04:36 PM ET (US) It's going to take a lot of JB Weld to seal those tanks. They put the stuff in and then roll it around to coat all the inside surfaces. The first tubes will have set up before you squeeze out the 100th. ;-)