1986 18 Outrage fuel tank replacement

[Piper]

The time has come! I will be removing deck for the dreaded fuel tank replacement. Thanks to all the fantastic resources archived here at CW, I feel well prepared.
Would appreciate any input from members that have been down this road & may have done things differently.

Thanks

[Maverick]

Hi Piper - recommend you look at this thread on fuel tank checking: viewtopic.php?f=6&t=492

[Phil T]

There have been over two dozen members who have inspected and replaced their below deck tanks.

Here is one discussion on the Outrage 18 specifically from the archive:
http://continuouswave.com/ubb/Forum3/HTML/021024.html

Here is the search list for all the Outrage 18 tank replacement discussions from the archive:
https://www.google.com/search?hl=en&source=hp&biw=&bih=&q=site%3Acontinuouswave.com&q=Outrage+tank+replacement&btnG=Google+Search#hl=en&q=site:continuouswave.com+Outrage+18+tank+replacement

[Piper]

The gasket material at the aft fuel pick-up or inspection plate is squeezing out; it resembles white lithium grease clinging to the perimeter. There is a strong fuel odor when [the leaking material] wiped away. The tank is always kept full.

The machine screws that fasten the inspection plate to the tank appear to be stainless steel. I tried to remove the screws, but they won't budge.

Based on the age of tank and its lifetime of saltwater use, it is time to replace the tank.

I replaced the fuel filler hose when ethanol hit the market. I will be replacing the fuel filler hose again along with the vent hose. The 90-degree-bend at the deck has a rather large radius. To reinstall the deck cover was tough. Are they any tricks [to use when reinstalling the deck cover]?

I am planning to replace the wiring and cables while the boat deck is removed. Also I am considering moving the boat batteries to the center console just to get them out of the stern splash well. [Moving the batteries will mean] I will give up some storage space--which is at a premium. I'll have to give it some thought.

Maverick: Thanks--very informative. Feel free to email any other photos you think may help.

Maverick: Did you epoxy-coat [your new fuel] tank exterior?

Maverick: Is your fuel filler hose one piece?

[Piper]

Phil: Thank you. I am very curious to see if any water is trapped under foam.

[Maverick]

Hi Piper...check your email.

No, did not coat the tank...I read pros and cons for doing so, and decided against it as I read a theory that bare aluminum forms a coating by itself to protect from salt corrosion as some unpainted navy ships ... Me not being a chemist or metallurgist...I thought I'd try that as it sounded reasonable.

I think the filler hose is 2 pieces if memory serves.

Yes, the screws for the inspection port on my tank were hard to get out too, but once I saw all the corrosion holes in the tank, it didn't matter anymore as I was going to replace the tank new anyhow.

I am very pleased with the build from Carr industries, they delivered on their promise.

Let us know what you find on yours...very curious. Thanks, Mav

[Piper]

admirable intel Mav! I was somewhat undecided regarding foaming new tank in place however, once I read your thread about how foam potentially sealed tank failure, I plan on re-foaming new tank in place. I'm undecided on whether i"ll be installing some type of "dip tube" within aft tank cavity(allowing removal of trapped water), I think this may actually add to ingress of unwanted water.
Thanks again

[Piper]

Pulled out the tank this weekend. The majority of corrosion was in aft base & vertical tank wall (very similar to maverick's photos). There was approximately 1-quart of foul smelling water trapped under tank.
Used a reciprocating saw very carefully to remove Whalers poured in foam around perimeter of tank. Blade was coming out dry on three sides of tank with exception to aft end of tank.
That foam is some tough stuff! One thing I did notice was there was little to no foam adhesion on wet end of tank. The foam was not adhered to the aluminum in that area. The foam bonded well elsewhere. I guess over the course of thirty years, all that excess sump water finds its way in there & may break the bond.
Thanks to all ,
Piper

[Dashriprock]

Im right there with you piper. I just removed the center console and deck. The deck peeled right off the fiberglass. Mine is a 1985 18 outrage. Next step for me is to rebuild decking and remove fuel tank. I started to saw out foam but that was tough. I am going to try powerwasher technique and then possible 2x6 jack lifting with of tank if necessary as described in previous posts.

Does anyone have guidance on rebuilding underside of deck. Ive heard of a carbon foam carbon composite using raka resin. I am in seach of any thoughts on any techniques to rebuild underside of deck.

[Dashriprock]

Oh I forgot the part about me impailing my leg with crowbar and am in hospital dealing with infection and 7 stitches later. This occured while trying to remove form around fuel tank. So I have a lot8t of time to reseasch and read threads!

[Piper]

Dashriprock, sorry to hear about your deck. I am fortunate, my deck is in good condition, one less project. Try this link http://continuouswave.com/ubb/Forum3/HTML/010762.html it is extremely informative.
I was able to remove fuel pick-up/inspection cover with cordless impact drill driver. Much to my surprise not one machine screw broke. Once removed I placed a pipe inside tank, hooked it with a block & tackle, away she went. I'm sure floor jack across 4" x4" resting on gunwales will do the trick.
Picked up my tank this week, not sure when I'll be putting it in. Hope your leg is doing better, Good luck!
Piper

[jimh]

Refurbishment of the central fuel tank cover decking is beautifully illustrated and described in detail in the REFERENCE section. See

http://continuouswave.com/whaler/refere ... store.html (Read both parts)

and also the never-finished article at

http://continuouswave.com/whaler/refere ... epair.html

[Dashriprock]

Piper. Thanks. I would imagine that your tank and my 85 tank are same size. Let me know if you are going through FMT or have alternative solution. I would even consider smaller tank and moeller product. If you or someone else has done so that would be interesting to see what they did.
Cheers

[Dashriprock]

Thanks Jimh great intel! My son and I will be back in action soon on the project.

[Piper]

Dash,
Spoke with FMT a while back. The tank was out of production but, still able to fabricate. They were unable to due it solely on; tank model #; capacity; year; make; model of boat. They did require detailed drawings for a positive outcome. Cost of shipping to north east was the deal breaker. I was able to find a local fabricator that did an outstanding job.

Regarding downsizing of tank, I think all that fuel under foot adds to the boats low center of gravity & great ride. Granted, I have never once burned an entire tank of fuel on one single outing but, I'm sure many have. I must admit that I did consider shortening up aft end of tank. I thought this would help since sump spillover into tank bathtub could potentially be eliminated via added bilge pump. Also, added storage would be beneficial. My deck is intact, I just couldn't justify all the modifications. If my deck was compromised beyond repair, I may have given it further thought.

Let me know what your plans & outcome are.

Piper

[Maverick]

Dash - The following link contains a source where I bought my tank (1987 whaler 18)...mine was about $900 and looked great.

viewtopic.php?f=6&t=492

[Dashriprock]

I am now sourcing a local fabricator. Tank is about ready to come out after I take the remaining gas. Looking at a closed cell foam surrounded with glass as the core below the deck "skin" that I removed. Amazing how wavy the decking is when laying flat and stripped of the rotted wood core.
Thanks for everyone input. Ill get some pics soon.