CONTINUOUSWAVE

Q1: what is a source for an Amiri-kart Corporation Model 11501 fuel tank as used in a 2009 220 OUTRAGE?

BACKSTORY
I have a 2009 220 Outrage. It has a 115-gallon plastic fuel tank. It’s stamped Ameri-kart Corp. Model 11501. I removed the fuel sender from the tank to replace the gasket due to leaking fuel and vapors. I discovered a previous owner had attempted a half-ass repair on the sender screw holes. I need a new tank.

Before abandoning the original fuel tank, perhaps you can contact the manufacturer or Boston Whaler customer service, and ask them for advice on how to repair the threaded holes that you report as being damaged by a prior repair attempt.

You may be able to use epoxy resin with thickener as a repair adhesive, and then tap new threads into the original holes.

If the tank is made with ultra high molecular weight (UHMW) material, epoxy resin won’t be able to bond well with it, but there may be some special compounds that will be able to adhere to it.

Thanks for another informative response JimH.

Based on the appearance of the plastic tank, someone has already tried using epoxy resin, but [the bond between epoxy and the plastic material of the tank] definitely didn’t take.

The area where the screws are intended to fasten into is reinforced. Unfortunately the space between the screws is not reinforced. There is just a thin tank top, [with material thickness of] maybe 1/8-inch at best.

I have a few calls into my local Boston Whaler parts departments. The tank is obsolete.A replacement that is under $700 may be available, but Boston Whaler headquarters are closed until [after this 4th of July holiday weekend.

I am keeping my fingers crossed because [$700 is] a lot less than I anticipated [for the cost of a new tank]

ASIDE: HOW I GOT INTO THIS PROBLEM
I’ve been told a million times to always have a marine survey done [when buying a used boat]. The [selling] dealer talked me out of having a surveyor inspect the boat. Lesson learned.

Although I’ve had to spend more than I would like, I still love the boat. And I hope that after this repair the 2009 220 OUTRAGE boat will be in top shape.

Jcomeau0 wrote:...someone has already tried using epoxy resin, but [the bond between epoxy and the plastic material of the tank] definitely didn’t take.

The inference from that remark is the tank is probably made of a UHMW plastic. Only special adhesives will bond with UHMW.

I haven’t heard from [Boston Whaler] if a direct replacement [plastic] OEM fuel tank is available for an 2008 220 OUTRAGE.

Summer is short. The turn around time [for something unspecified] is at least two weeks. I may have an aluminum [fuel] tank fabricated.

On my 2009 220 OUTRAGE the fuel tank is not foamed-in-place, and [the new] aluminum [fuel tank I might have fabricated] won’t be [foamed-in-place] either.

Q2: what concerns will there be with a fuel tank made from aluminum?

Everyone [apparently means all of the group of people to whom he has asked directly about using an aluminum fuel tank] have stated to have [the aluminum tank painted with ] coal-tar-epoxy, but all the fabricators [that have been consulted] state they don’t do that.

It’s my understanding that [the fuel tank] won’t need [to be painted with a coal-tar-epoxy on surfaces] where [the fuel tank] is not foamed-in-place.

Q3: where in the vicinity of Boston, Massachusetts is there a service provider that can accept for disposal 100-gallons of gasoline [probably from from the fuel tank on the boat]?

Jcomeau0 wrote:Q2: what concerns will there be with a fuel tank made from aluminum?

Aluminum welded fuel tanks have been used as gasoline tanks in boats for decades.

A common concern with aluminum as a gasoline fuel tank is for corrosion to be created by the presence of water, either water inside the fuel tank and sitting on the bottom of the tank, or water on the outside of the fuel tank, held in contact with bare aluminum surfaces, often in closed areas where there is little ventilation or chance for evaporation of the water, and the water is held in foam or other materials that are pressed against the sides or bottom of the fuel tank.

I have the same exact boat [that its, this new participant in the thread apparently has a 2009 220 OUTRAGE]

NEED INFORMATION
I need [the thread initiator to measure] the depth [of the fuel tank on his 20098 220 OUTRAGE] from the hole [on the top of the fuel tank where the fuel tank level] sender is located to the bottom [of the fuel tank].

PLAN FOR FUTURE
I plan to remove an ultrasonic [fuel tank level] sender, and [change to a fuel tank level electrical sender that uses] mechanical reed switches.

Q4: is the [fuel tank level sender on the 2009 OUTRAGE 220 owned by the thread initiator] made by a brand called SSI and uses three wires?

Jcomeau0 wrote:Q3: where in the vicinity of Boston, Massachusetts is there a service provider that can accept for disposal 100-gallons of gasoline [probably from from the fuel tank on the boat]?

Disposing of fuel should be easy. Start with your vehicles by filling the tanks with the Outrage fuel. Next fill your friends tanks followed by neighbors. In case the fuel is a bit old add some Stabil or another fuel stabilizer of your choice before transferring the fuel.

OK,a new tank is an expensive option. You say the tank has been modified, send some pics.

If I remember correctly the sender screws have threaded inserts in the tank so the screws don't strip. If the inserts have been compromised you can replace them with nut-serts. Relatively unkown except in aviation circles, they will replace a threaded insert with ease. I have the tool (expensive) and some inserts. Like I said pics would help.