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Author Topic:   1999 18 Dauntless Fuel Fill

masbama posted 07-01-2014 09:29 AM ET (US)
When the summer heat hits (as it did this week) it causes gasoline to spew back out of the fuel filling cap [on a 1999 DAUNTLESS 18]. It concerns me because [spilled gasoline] can get down into the bilge where there are electrical wires and such. The Whaler guy at the boat show, as well as a customer service representavive, suggested a new fuel fill cap. The one I have now is the combo fill cap and vent which does not work very well. Has anyone ever replaced this part? Thanks!
Jefecinco posted 07-01-2014 09:53 AM ET (US)
Under warranty in 1999 the filler cap was replaced on my 1999 Dauntless 16 using a package provided by Boston Whaler.
The original cap was replaced by a conventional non-vented cap and the vent hose was rerouted to the port hull side where a conventional through hull vent fitting was installed.
This solved the problem of tediously slow tank fill ups and fuel spillage from the cap area.
Butch
masbama posted 07-01-2014 10:17 AM ET (US)
Thanks Butch. When I mentioned that to the whaler guy at the boat show he suggested not going that route but to try a new cap first. That said, did you use the whaler dealership and if so would you recommend them for service?
Jefecinco posted 07-01-2014 07:16 PM ET (US)
If the cost will be borne by you I would try a new cap first.
My dealer was Killinger Marine of Pensacola who has since been bought out by MarineMax of Pensacola and Gulf Shores.
I have not yet had an occasion to try their service department. I've met and talked with the service manager at the Gulf Shores store and was favorably impressed. I expect they would do their best to satisfy you.
Butch
masbama posted 07-01-2014 08:24 PM ET (US)
Thanks. I was at the Gulf Shores location last week but did not talk with the service manager. Glad he came appeared as a positive sorta fella.
contender posted 07-01-2014 09:08 PM ET (US)
Something does not sound right, with the sun heating up the gas and expanding it, the gas should come out of the vent not the gas cap. You better check your vent line/hose for a blockage or kink in the hose.
masbama posted 07-01-2014 09:39 PM ET (US)
Well it is one of those caps where the vent hose is attached to the cap so in a way you answered my question. If the gas expands from heat it would have no where else to go so it would have to spew out of the cap. Thought BW would have a better system than that without a major modification like Butch had done.
Jefecinco posted 07-02-2014 09:40 AM ET (US)
I believe the way that cap is supposed to work is that when vapor is vented through the cap assembly any fuel is supposed to return to the tank via the fill hose. Actually fuel should not be getting through the vent hose at all but we know how much those plastic tanks can expand and become pressurized in the heat of summer. The Moeller tank on my Sport 13 looks like a football until I release the pressure.
Consider a couple of things. First, if your boat is on a trailer try lowering the tongue to raise the fuel cap. Second, check the condition of the fuel cap gasket. If you are able to see the vent hose check to see if it is routed to the filler cap so that it is higher than the tank at some point. It won't hurt to blow some air through the vent hose to ensure it is not restricted which is admittedly a remote possibility in your more or less closed loop system. But, if the hose is restricted when the fuel expands it has no where to go except the filler hose.
I know exactly what you are talking about. The area around the fuel fill cap on my Dauntless was always stained in the summer if I kept the tank full until the modification mentioned previously was applied.
Butch

masbama posted 07-02-2014 09:13 PM ET (US)
Thanks so much. At least I'm not alone. I lowered the bow and then tried to blow air through the vent hose but the opening is covered by a plastic piece so it was hard to get a hose through. After the initial gushing of gas it seemed to lower and has not spewed out again. Might try to replace cap but the it still is not a strong system. Tried to link pics. Thanks!
http://s775.photobucket.com/user/masbama/library/Dauntless%20Fuel

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Author	Topic: 1999 18 Dauntless Fuel Fill
masbama	posted 07-01-2014 09:29 AM ET (US) When the summer heat hits (as it did this week) it causes gasoline to spew back out of the fuel filling cap [on a 1999 DAUNTLESS 18]. It concerns me because [spilled gasoline] can get down into the bilge where there are electrical wires and such. The Whaler guy at the boat show, as well as a customer service representavive, suggested a new fuel fill cap. The one I have now is the combo fill cap and vent which does not work very well. Has anyone ever replaced this part? Thanks!
Jefecinco	posted 07-01-2014 09:53 AM ET (US) Under warranty in 1999 the filler cap was replaced on my 1999 Dauntless 16 using a package provided by Boston Whaler. The original cap was replaced by a conventional non-vented cap and the vent hose was rerouted to the port hull side where a conventional through hull vent fitting was installed. This solved the problem of tediously slow tank fill ups and fuel spillage from the cap area. Butch
masbama	posted 07-01-2014 10:17 AM ET (US) Thanks Butch. When I mentioned that to the whaler guy at the boat show he suggested not going that route but to try a new cap first. That said, did you use the whaler dealership and if so would you recommend them for service?
Jefecinco	posted 07-01-2014 07:16 PM ET (US) If the cost will be borne by you I would try a new cap first. My dealer was Killinger Marine of Pensacola who has since been bought out by MarineMax of Pensacola and Gulf Shores. I have not yet had an occasion to try their service department. I've met and talked with the service manager at the Gulf Shores store and was favorably impressed. I expect they would do their best to satisfy you. Butch
masbama	posted 07-01-2014 08:24 PM ET (US) Thanks. I was at the Gulf Shores location last week but did not talk with the service manager. Glad he came appeared as a positive sorta fella.
contender	posted 07-01-2014 09:08 PM ET (US) Something does not sound right, with the sun heating up the gas and expanding it, the gas should come out of the vent not the gas cap. You better check your vent line/hose for a blockage or kink in the hose.
masbama	posted 07-01-2014 09:39 PM ET (US) Well it is one of those caps where the vent hose is attached to the cap so in a way you answered my question. If the gas expands from heat it would have no where else to go so it would have to spew out of the cap. Thought BW would have a better system than that without a major modification like Butch had done.
Jefecinco	posted 07-02-2014 09:40 AM ET (US) I believe the way that cap is supposed to work is that when vapor is vented through the cap assembly any fuel is supposed to return to the tank via the fill hose. Actually fuel should not be getting through the vent hose at all but we know how much those plastic tanks can expand and become pressurized in the heat of summer. The Moeller tank on my Sport 13 looks like a football until I release the pressure. Consider a couple of things. First, if your boat is on a trailer try lowering the tongue to raise the fuel cap. Second, check the condition of the fuel cap gasket. If you are able to see the vent hose check to see if it is routed to the filler cap so that it is higher than the tank at some point. It won't hurt to blow some air through the vent hose to ensure it is not restricted which is admittedly a remote possibility in your more or less closed loop system. But, if the hose is restricted when the fuel expands it has no where to go except the filler hose. I know exactly what you are talking about. The area around the fuel fill cap on my Dauntless was always stained in the summer if I kept the tank full until the modification mentioned previously was applied. Butch
masbama	posted 07-02-2014 09:13 PM ET (US) Thanks so much. At least I'm not alone. I lowered the bow and then tried to blow air through the vent hose but the opening is covered by a plastic piece so it was hard to get a hose through. After the initial gushing of gas it seemed to lower and has not spewed out again. Might try to replace cap but the it still is not a strong system. Tried to link pics. Thanks! http://s775.photobucket.com/user/masbama/library/Dauntless%20Fuel