[C320-list] My fuel tank leaks!

[jonvez at comcast.net]

Ray,
First of all, thanks for the advice on removing the tank from the aft cabin access--saved me a lot of time!

For those of you who may have to go through this, this is how I successfully removed and installed a new tank yesterday--

I found that I too had a pinhole leak in a weld--looks like the tank had enough room to move around a bit and I'm sure this didn't help. The newer tanks are thicker (my original was .90mm and the 'new' one .125mm). I got the tank from Catalina in two days, but it was manufactured in July of 04. Didn't come in a box, so it was pretty scratched up when I got it, so I hope it holds!

To remove the fuel: I ended up using a Siphon Mate, which is a simple pump that costs $27.99 at Defender. I also  bought a pump that fits on a drill and is a simple impeller for 15 bucks at a hardware store, but my drill wasn't powerful enough, so I went with the hand pump.

To remove the old tank: The was much easier than I anticipated. Once empty it came right out using the aft cabin access panel (the lazarette is about a 1/2" to small (thanks again Ray!). You need to unscrew all of the connections holding the hoses in place and remove the boards over the tank. The board to port was a pain to remove and if I ever have to do this again, I will trim it to get it in and out more easily.

The new tank: Catalina sent me the tank with the fuel inlet and return connections both pointed in the wrong direction and the barbs too small for the hoses! Changing out the hoses wasn't an option because all of the connections on the engine side call for the hose size already in the boat. To solve this problem, I took the connections from the old tank and refit them onto the new tank. The problem is that the old hose barbs are made of bronze and I had no way of isolating these from the aluminum tank other than teflon tape. So I will be calling the tank manufacturer tomorrow to see if I can get the right size barbs in aluminum (West and others don't seem to carry and I can't find a stainless insert to separate the two metals.

Overall, it was an all day job and not one I want to do again, but it wasn't an impossible task. I am very frustrated that the old tank 1) failed so soon, and 2) Catalina didn't provide me with a drop in replacement ($377 plus shipping by the way).

Finally, I did get a chance to check the condition of the fuel and tank as far as sludge and I'm very pleased to find that I had no sludge and the fuel was extremely clean! So I will continue with my regimen of keeping the tank topped up and using Biobor as a anti-microbial....If anyone is interested in more detail, let me know...Thanks to everyone who provided advice!

Regards,

Jon Vez


-------------- Original message -------------- 
From: "Ray Durand" <durand.mail at verizon.net> 

> Jon, 
> 
> Mine failed after two years! 
> 
> In my case, one of the welded seams had a tiny pin hole in it. It took me 
> weeks to find it. I share your pain. 
> 
> Looks like you already have some advice on getting the fuel out. This is 
> very important, since you need to get it all out in order to be able to move 
> the tank around to get it out. I discovered that the only way to get the 
> tank out is through the aft cabin access opening. You have to remove the 
> wooden frame around the opening and the tank will just fit through it. Mine 
> had a metal strap that secured the tank to the hull. It was not reusable, 
> so I cut it with a pair of metal cutters - not too hard as I remember. 
> 
> After disconnecting the hoses and the wiring to the sensor, you have to get 
> the tank over to the port side so you can fit it through the aft cabin 
> opening. I got a new tank from Catalina (Frank later reimbursed me, even 
> though my boat was out of warranty). Installing the new tank was just a 
> reverse of the removal process. I bought a tank hold down strap from my 
> local boating store and resecured the tank. Keep the old sensor. I didn't 
> and my new sensor isn't nearly as accurate as the old one. The sensor is 
> easily replaced. 
> 
> Good luck! 
> 
> Ray Durand, #822 
> Marina del Rey 
> 
> 
> ----- Original Message ----- 
> From: 
> To: "320 List" 
> Sent: Monday, August 21, 2006 5:32 AM 
> Subject: [C320-list] My fuel tank leaks! 
> 
> 
> > Well I confirmed the worst case scenario this weekend. My fuel tank is 
> > indeed leaking somewhere on the bottom. I will be calling Catalina this 
> > morning to get a new tank, so any advice on removing the tank and removing 
> > the fuel in the tank would be greatly appreciated. Hopefully I can get one 
> > quickly enough to not end the rest of my season :( 
> > I took a look at what Nigel Calder had to say about fuel tanks and was 
> > quite surprised to read that a study conducted by the ABYC revealed a tank 
> > life for aluminum to be between 7.6 years and 17 years! Production and 
> > quality control seem to make the difference in the life of the tanks. My 
> > boat is a '99, so this seems really premature. 
> > 
> > Does anyone have a suggestion on the type of transfer pump I can use 
> > (siphoning is not an option).? Someone at the marina mentioned that there 
> > is pump that can be attached to a drill and is okay to use with diesel, 
> > but haven't been able to find one...Thanks in advance for any advice! 
> > 
> > Regards, 
> > 
> > Jon Vez 
> > 
> 
> 
>