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Author Topic:   1984 Outrage Fuel Tank Replacement

dkand3 posted 03-14-2014 09:52 PM ET (US)
Looking for guidance on how [apparently means how to replace the fuel tank on a 1984 Boston Whaler OUTRAGE of unknown hull length]. Any help greatly appreciated
Marko888 posted 03-14-2014 10:54 PM ET (US)
Google is your friend. Do a search and you will find several articles about it for 18-22' Outrages.
Buckda posted 03-15-2014 10:52 AM ET (US)
First step is to drain and expose the tank. De-rig the whole boat and remove the tank cover, and make sure you've siphoned as much fuel out of the tank as possible.
Next, remove the aluminum retainers that should go across the top of the tank, and remove all of the fuel fill and vent hoses.
Next, use a standard carpenters saw to cut the foam around the tank. You may also have good results using a small scraper or other improvised tool to remove the foam around the edges of the tank.
The next step has been debated. Several here have said that you can simply pry out the tank using a 2x4 cut to fit into the space between the tank and the bulkhead and pry it out.
I used an overhead lift. Your tank was likely caulked in place underneath, and there will be some foam that you can't get to with the saw that will be adhering the tank to the bulkhead too. I had to overcome both to get my tanks out of my 25' Outrage.
Once out, you can make a determination of condition and if you want to order an OEM replacement or have one custom made for you.
Buckda posted 03-15-2014 10:55 AM ET (US)
The only other thing to consider - once you have that tank out, it's a good time to do other repairs. Check that deck/tank cover to see if it needs repair; and this is an excellent time to replace wires, etc that run in the rigging tunnels.
If your boat is like mine, you likely have some slight blistering in the rigging tunnels and will want to repair that gelcoat there as well as address numerous other things that are exposed once you remove that deck!
Down the rabbit hole you go!
picflight posted 03-20-2014 11:06 AM ET (US)
By "De-rig the whole boat," you mean remove the wiring from the console end? How do you keep track of how the wires are reconnected?
hauptjm posted 03-20-2014 12:27 PM ET (US)
When the job gets to the point of tank replacement, utilize the OEM provider for Whaler tanks from that era, Florida Marine Tanks (FMT). I used them to replace the 63 Gal. tank in my 1985 Outrage 18: fit like a glove.
http://www.floridamarinetanks.com/
Jefecinco posted 03-20-2014 06:09 PM ET (US)
To keep track of wires use labels. I believe they are available from Radio Shack, Graingers, etc. Another good move is to take close up photos so you can use them for reference when reconnecting.
Butch
JMARTIN posted 03-20-2014 06:34 PM ET (US)
I took my old tank to a tank guy. He built me a new tank using my existing: fill, vent, fuel gauge sender unit and supply off of my old tank.
My tank popped right out using the sturdy 2X4 technique. I would have tried to pop it out sooner in the foam removal process if I would have known it would pop out so easy.
John
dunstr posted 03-27-2014 05:36 AM ET (US)
Use florida marine tanks just tell them the year and size of your boat and they ship directly to your front door I am currently in the process of this now with my 1984 18' outrage.
Slippery Eel posted 03-28-2014 01:47 PM ET (US)
I just received my new 77 gal tank for my 88 Revenge. Ordered directly from Florida Marine Tanks. They do a nice job and it is a perfect match. Drained the fuel and pulled the tank last weekend. Pretty pitted up after spending 25 years in salt water soaked foam. It was ready for a change. I will definately have one less thing to worry about this season.

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Author	Topic: 1984 Outrage Fuel Tank Replacement
dkand3	posted 03-14-2014 09:52 PM ET (US) Looking for guidance on how [apparently means how to replace the fuel tank on a 1984 Boston Whaler OUTRAGE of unknown hull length]. Any help greatly appreciated
Marko888	posted 03-14-2014 10:54 PM ET (US) Google is your friend. Do a search and you will find several articles about it for 18-22' Outrages.
Buckda	posted 03-15-2014 10:52 AM ET (US) First step is to drain and expose the tank. De-rig the whole boat and remove the tank cover, and make sure you've siphoned as much fuel out of the tank as possible. Next, remove the aluminum retainers that should go across the top of the tank, and remove all of the fuel fill and vent hoses. Next, use a standard carpenters saw to cut the foam around the tank. You may also have good results using a small scraper or other improvised tool to remove the foam around the edges of the tank. The next step has been debated. Several here have said that you can simply pry out the tank using a 2x4 cut to fit into the space between the tank and the bulkhead and pry it out. I used an overhead lift. Your tank was likely caulked in place underneath, and there will be some foam that you can't get to with the saw that will be adhering the tank to the bulkhead too. I had to overcome both to get my tanks out of my 25' Outrage. Once out, you can make a determination of condition and if you want to order an OEM replacement or have one custom made for you.
Buckda	posted 03-15-2014 10:55 AM ET (US) The only other thing to consider - once you have that tank out, it's a good time to do other repairs. Check that deck/tank cover to see if it needs repair; and this is an excellent time to replace wires, etc that run in the rigging tunnels. If your boat is like mine, you likely have some slight blistering in the rigging tunnels and will want to repair that gelcoat there as well as address numerous other things that are exposed once you remove that deck! Down the rabbit hole you go!
picflight	posted 03-20-2014 11:06 AM ET (US) By "De-rig the whole boat," you mean remove the wiring from the console end? How do you keep track of how the wires are reconnected?
hauptjm	posted 03-20-2014 12:27 PM ET (US) When the job gets to the point of tank replacement, utilize the OEM provider for Whaler tanks from that era, Florida Marine Tanks (FMT). I used them to replace the 63 Gal. tank in my 1985 Outrage 18: fit like a glove. http://www.floridamarinetanks.com/
Jefecinco	posted 03-20-2014 06:09 PM ET (US) To keep track of wires use labels. I believe they are available from Radio Shack, Graingers, etc. Another good move is to take close up photos so you can use them for reference when reconnecting. Butch
JMARTIN	posted 03-20-2014 06:34 PM ET (US) I took my old tank to a tank guy. He built me a new tank using my existing: fill, vent, fuel gauge sender unit and supply off of my old tank. My tank popped right out using the sturdy 2X4 technique. I would have tried to pop it out sooner in the foam removal process if I would have known it would pop out so easy. John
dunstr	posted 03-27-2014 05:36 AM ET (US) Use florida marine tanks just tell them the year and size of your boat and they ship directly to your front door I am currently in the process of this now with my 1984 18' outrage.
Slippery Eel	posted 03-28-2014 01:47 PM ET (US) I just received my new 77 gal tank for my 88 Revenge. Ordered directly from Florida Marine Tanks. They do a nice job and it is a perfect match. Drained the fuel and pulled the tank last weekend. Pretty pitted up after spending 25 years in salt water soaked foam. It was ready for a change. I will definately have one less thing to worry about this season.