Fuel Tank Replacement

Sooner or later, we're all gonna be faced with this. There's alot of bad information given on this subject. I've read it all, good and bad. Some of the ways I've read were downright scary. I've heard of filling the holes with marine tex and wrapping the tank in fiberglass. I kid you not !!

First, I do not belive in the repairing of an aluminum fuel tank. In my professional opinion. I just don't reccomend it. It's replacement only. And while you are at it, the replacement of all components. "Compontents" being fuel lines, clamps, whatever. Do it all and be done with it.


Aluminum tanks need to have a protective coating put on them,it will make the tank last a very long time. I use and recomend Interprotect 2000e. Itt's an epoxy barrier coating. Before anything is applied to the aluminum, it needs to first be cleaned, scuff sanded, then cleaned again, then chemically etch primed. Failure to follow these steps,WILL result in a failure of your coating. For the chemical etch prime, I use and recommend West System 860 aluminum etch kit:

http://www.jamestowndistributors.com...t.do?pid=12214

After the surface is chemically prepped,the Interprotect is applied. You want to apply this to a thickness of 10mils. You can use a matchbook cover as a guide. DO NOT USE THE NUMBER OF COATS TO DETERMINE THICKNESS. For the coating to protect completely needs to thick enough. Otherwise it's a waste of time. Rhino Lining is a complete waste of time. I've read of people doing this and the coating ended up failing in a very short time. Wrapping a tank in fiberglass is also a waste. The fuel tank,done in the way I described, will last indefinately. Using this method, the tank is completley isolated from any and all mositure...

http://www.yachtpaint.com/docs/gb_ISO_I_5000186.htm


I use and recommend Starboard strips to chock the tank in place. Cut the Starboard in strips. Use the only product that will actually bond starboard; it's called "Starbond". Use this to adhere the strips to the hull. I'm unaware of any other product that will adhere Starboard. Test fit the tank. After you've laid it in make sure it's not rocking anywhere. The tank must sit evenly and securly. Rocking will likely fail due to stress fracturing. If the tank sits well pull it back up. Coat the strips in 3m 5200. This will create a gasket. The idea is not to glue the tank in palce. The 5200,keeps water away between the strips and the tank. Secure the tank by chocking. After the tank is secured, it is time to check the ground on the tank and the fill plate,i usually replace the ground wires for both the tank and the fill plate. Definitely change the fuel lines and be sure to protect them from chafing. Soft wall exhaust hose works like a champ.

I use and recommend Patriot Marine in Ware Town, NJ. I can drop off the old tank and they will make me a duplicate. These guys are the best in my opinion http://www.patriotmarinefab.net/

There's a company down south, they build a tank and coat it. The coating is a cheap enamel paint and it will fail in about 1-2yrs tops. Yes, there's a huge difference between tank mfg's...

i hope this helps everyone...