Fuel Tank Replacement Without Foam Surround

[floater]

I'm in the process of finally putting the rejuvenated fuel tank back into my 1988 Revenge 20 W-T. I have the tank in place and strapped down, and I'd like to not use the foam around it. I was wondering if I could fill the space around the tank with pool-noodles or anti-fatigue mats? My idea is to allow water to remain free flowing. I've installed a 1/2-inch tube through the lower hole in the starboard side of the tank cavity (that the bonding wire used to go through), and this hose will get plugged into a 12-volt pump I will use to drain the tank cavity when ever it rains. I can't find any informationabout what would happen if the pool-noodles or anti-fatigue mats ever come into contact with gasoline in case of another leak.

I will post pics when the job is done. Thanks

[floater]

The tank as installed. At the bottom of the tank you can see the Viton® rubber strips I used to support the tank. They are impermeable to gasoline.


The 12-volt pump I am going to use to drain the tank cavity whenever it fills with water.


The 1/2-inch hose passes through the side of the tank cavity wall and is secured to the side. No holes needed to be drilled.


This morning, I poured some gasoline onto a piece of the anti-fatigue mat, and it didn't appear to affect mat. If the mat hold up by tomorrow I will rinse with water and see if it retains any gasoline smell.

[jimh]

That is a very nice installation and a good solution to the problem of water collecting in the central fuel tank cavity of classic Boston Whaler hulls.

Please give more details about the pump you chose. Apparently the pump is self-priming and can provide a large amount of lift. It looks like the pump is at least 18-inches above the bottom of the fuel tank cavity, perhaps more. It takes a good pump to be able to self-prime with that much lift.

You will need some sort of fill material to surround the fuel tank. I think it is liable to move if not well restrained by the surrounding material if the boat encounters some large seas and the hull is slammed hard in waves.

[jimh]

If you still have the central deck section removed, please take a few images to show how the fuel filler hose is routed to the tank from the fuel filler inlet on Port side. Thanks.

Viton is brand name of a synthetic rubber compond. For more information see

https://en.wikipedia.org/wiki/Viton

[floater]

The pump is from Princess Auto. You equivalent down there is Harbour Freight. It claims to have a 26 foot lift capacity. The directions state to put a few drops of oil into the inlet prior to use the first time or after prolonged dry periods. I have installed cup up fatigue mats around the sides of the tank. They appear to be jammed in there very tight. I will take more pics and post tomorrow.

Here is the only pic I have of the fuel filler and vent hose. I will take more tomorrow as well.

http://i123.photobucket.com/albums/o316 ... txfqnt.jpg

[floater]

Here is a pic of the entire fuel hose inlet and vent system.

http://i123.photobucket.com/albums/o316 ... 9fac1o.jpg

This is the finished install now before putting the floor back on.

http://i123.photobucket.com/albums/o316 ... ottlei.jpg

http://i123.photobucket.com/albums/o316 ... 5ckt5r.jpg

My only concern is the gasket material I used to form the 6 inch gasket around the fuel inlet opening. When you stick your nose right against the plate you get a slight smell of gas. I'm going to caulk around the plate and gasket with some gasoline resistant gasket caulking and hope that holds. If not it looks easy enough to remove this inlet plate with the floor on for a future repair.

[floater]

I finished the install of the tank and floor and all the fishing stuff.

http://i123.photobucket.com/albums/o316 ... qyiwcl.jpg

One thing I'm curious about though is that the tank doesn't appear to be aligned with the access hatches. I thought that the dual pick up would be centered in the opening for the rear deck hatch and it is not. The fuel gauge as well appears to be off to one side. Were these tanks put in originally more towards the starboard side?

I decided not to caulk the floor seams at this time. I'm going to leave it like that till next season and pull up the floor again just to take a look and see how much water actually gets in there from the seams.