Fuel leak and possible fuel tank replacement

[Thombo]

I'm a newbie to boating, but have auto mechanical experience.

I have a 17ft. '94 Thompson I/O and I'm getting fuel pouring out my drain plug when draining after a day on the water. I have had the marina look at it and they replaced the fuel tank sending unit, but it did not stop the leak. They are claiming it could cost me around a thousand to replace the tank (if that's it). I want to do it myself, but would like some advice first.

I'm assuming I'll have to take up the carpet and cut a hole in the floor board over the tank slightly larger than the tank itself. I don't want to go cutting into the floor board without some advice. I'm open to any and all suggestions/tech tips, etc.

The marina and I think the tank may have worn a slight hole in it by wear. Perhaps it's gotten a bit loose and is moving slightly in place and worn a tiny hole in it. Is this probable and does that happen often?

I'd appreciate help.

Thanks!

 

[achris]

Re: Fuel leak and possible fuel tank replacement

What is the tank made of? I have had 2 holes in my aluminium fuel tank in the 24 years I've owned the boat. The first was caused by corrosion and was repaired by welding a 'wear strip' along the length of the tank and the second was an incredibly small fracture that took me days to find. Just a spot of weld and that was fixed.

After the second leak I decided to fix the tank for good. I got some 'Redcoat' fuel tank sealer and lined the inside of the tank with it. I haven't had a problem since.

Chris.......
P.S. You're in the wrong forum, should be in the I/O section or the non-engine boat topics section.... Don't worry, I'll tell a moderator and have him move the thread.

 

[RWilson2526]

Re: Fuel leak and possible fuel tank replacement

What material is your tank? Aluminum or plastic? If its aluminum you very likely could have a hole in it.....rubbing a hole if its loose is a possibility or if its foamed in you could have gotten some water in your foam which will corrode your tank making holes from pin size to golf ball size. not sure how your marina thought changing your sending unit was going to stop a a leak .
Assuming you have at least inspection ports above your fill hose and vent hose connection make sure your vent hose and fill hose is tight and in good shape. Does it happen all the time every time you go out regardless of how much fuel is in the tank or maybe only the times after you fill up with gas?

depending on the size of your tank and if you can find a stock one a new tank will cost you around $300 . to pay a marina to do it would be $1000 easy especially if you have to pay someone to reglass the floor back in.

 

[robert graham]

Re: Fuel leak and possible fuel tank replacement

Gas in bilge is not good and don't want boat to become a fire-ball on the water. I would pull boat out, drain/pump tank, cut deck, replace tank. My brother-in-law is right in the middle of that, replacing a 60 gallon plastic tank with a new 40 gallon aluminum, had to remove t-top, center console, cut deck, quite a job, but better than gas leaks! Good Luck!

 

[MyViewGS]

Re: Fuel leak and possible fuel tank replacement

do you have a water separator? If yes, check connections there and at motor. I hope its simple like that. I just cut my old tank (90 gal.)out and am getting preped to install the new one (50 gal.). Luckily for me the boat had a large access panel in the floor. If you have to cut I suggest drain the tank and let sit for several days and then you still need to have alot of ventilation.

MyViewGS