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Author Topic:   2004 240 OUTRAGE Deck Repair
pecos23 posted 05-31-2015 10:42 PM ET (US)   Profile for pecos23   Send Email to pecos23  
I have a 2004 240 OUTRAGE, The [portion of the cockpit deck that covers the] fuel tank has gotten wet, and the aft portion is starting to rot and get soft. [Please share] experience with removing the [portion of the cockpit deck that covers the] fuel tank on later model OUTRAGE boats.

It looks like the console will [need to be] lifted, as the [deck that needs to be removed] runs under the console.

Also, has anyone heard of [the cockpit deck of a 2004 240 OUTRAGE] failing so quickly? It seems as if the water has entered under the deluxe leaning post, where the leaning post, fold-down seat, and live well are attached. The repair looks like a complex job, beyond my experience since, once it's removed, the bottom [reinforcement of the cockpit deck panel] will have to be stripped and rebuilt.

[I am] disappointed to say the least--350 hours on a rack-stored pristine boat. Soft decks make my stomach sick.

jimh posted 06-01-2015 10:38 AM ET (US)     Profile for jimh  Send Email to jimh     
To have a portion of the deck of a 2004 Boston Whaler boat become soft due to rot and decay of the wood that reinforces the underside of the laminated deck seems abnormal, to me. However, if the wood is now and has been wet, particularly with freshwater, there is always the possibility of rot.

Fresh water seems more harmful to wood than saltwater. If the boat were used in saltwater, perhaps it was often washed down with freshwater, and some of that water got into the wood.

There are plenty of anecdotal reports of loss of strength in deck areas caused by decay or rot of the wood reinforcement, but usually the boats are older than 11-years-old. However, 11 years is plenty of time for an incidence of water intrusion into the wood to make its effect known.

If the water appears to have entered under the seating structures, perhaps the fasteners for the seating were not well-sealed as they passed through the deck structure, and water intruded there.

I browsed the drawings for a 2004 Boston Whaler 240 OUTRAGE at


but I did not see a drawing that shows the cover for the fuel tank cavity area.

There can be no harm in contacting Boston Whaler customer service to seek their opinion about this problem. They should be very familiar with a c.2004 boat, its construction, and any procedures needed to make a repair. And, perhaps they may have some added support they could offer. It is worth a telephone call to speak with them.

conch posted 06-02-2015 09:43 AM ET (US)     Profile for conch  Send Email to conch     
When was the hull originally put in service? Maybe there is some warranty left,or possibly negotiate some help towards the repair.
Jefecinco posted 06-03-2015 07:36 PM ET (US)     Profile for Jefecinco  Send Email to Jefecinco     
A boat cover is always a good protective device.


jimh posted 06-04-2015 01:26 PM ET (US)     Profile for jimh  Send Email to jimh     
When your 2004 Boston Whaler 240 OUTRAGE was stored in a rack storage facility, was it:

--stored under cover of a building, or left outside?

--stored with the stern lower than the bow so water would naturally drain toward the transom?

--stored with the plugs removed from all drains in areas that could collect water?

vze2gbs4 posted 06-07-2015 01:30 AM ET (US)     Profile for vze2gbs4  Send Email to vze2gbs4     
Wow-it does sound odd that relatively newer hull like 04 would already have soft deck spots due to root-wonder if there was any defect due to fiberglass lamination part ( to thin ) that is resulting in failure.The right way to fix it is remove leaning post and lift center console high enough to slide back that center fuel tank cover-turn it over and see where the problem is-if indeed wet remove all rooten part and reinforce with fresh wood or whaler board,epoxy and fiberglass cloth . Big job but inevitable because root would never go away and only progress to worse over years.
picflight posted 06-11-2015 02:05 AM ET (US)     Profile for picflight    
Here is the diagram for your boat that shows the fuel tank cover.

Certainly a time consuming job but can be done in steps.

Day 1 - Disconnect the center console electrical and hydraulics.
Day 2 - Dismantle the leaning post/pedestal seats and live well.
Day 3- Remove seats and center console from boat.
Day 4 - Unscrew and remove fuel tank cover. PB240OR19%20Model%20%281%29.pdf

I have been through these steps on a smaller scale, your boat is a bit more work but certainly can be done with time and patience.

Once you get the tank exposed, I would replace the fuel tank as well.

Best of luck and post pictures.

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