[C320-list] A Diesel Fuel Tank Leak

[Ray Durand]

I had the same problem on my #822 when the boat was only a couple of years
old.  After several weeks of trying to find the source of the leak, I
discovered that the tank itself was leaking.  Removing the tank was not a
particularly easy job.  You need to first empty the tank - I bought a
inexpensive manual pump and a couple of 5-gallong fuel jugs.  After emptying
the tank, I disconnected the hose and fuel gauge sensor connections, and cut
the strap that holds the tank down. I think I may have even removed the
shelf on the starboard side - I'm not sure this is really necessary - it's
been a while!  I found that he only way to remove the tank was through the
aft cabin access door.  I had to remove the wood frame around the access
door to get the tank out. 

When I got the tank out, I discovered a very tiny hole in the bottom corner
weld (port side, forward corner).  I brought the old tank to Catalina (this
was when they were still building 320s in Woodland Hills) and purchased a
new one.  On my way back to the boat, I got a call from Frank Butler saying
that this shouldn't have happened and that he was going to contact the
manufacturer about it.  About a week later, I got a check from Catalina for
the full purchase price.  Remember, this was several years ago - I doubt
Catalina will do anything about your problem since the boat is 8 years old.

I needed to purchase a tank strap for securing the tank down again.  I found
it at a local boat store.  The original strap was a metal band that I had to
cut.  I seem to remember that Catalina used newspaper as insulation between
the hull and the tank.  I'm pretty sure the newspaper was in good shape and
I simply reused it when I installed the new tank.

One more thing - you might want to test the fuel sensor if your new tank
comes with one before you install it.  Mine did, and it doesn't work nearly
as well as the one on my old tank.  I wish I had kept my old sensor.  The
test is actually fairly simple using an ohm meter.  You can find out how to
do this by searching on the web.

Good luck with this.  If you have any more questions, let me know.

Ray Durand


-----Original Message-----
From: c320-list-bounces at lists.catalina320.com
[mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of Ken Danko
Sent: Monday, August 10, 2009 7:18 PM
To: C320-List at Catalina320.com
Subject: [C320-list] A Diesel Fuel Tank Leak

I have developed a diesel fuel leak. I only had a few minutes to look at 
it so I don't have all the details as I write this. I'm really surprised 
because it appears that the hoses and all connections are ok. The leak 
seems to be coming from the tank itself but I don't yet know where. 
Grace is a 2001 model so a tank failure seems to me to be highly 
unusual. The last time I was out on Grace, I hosted a post sailing BBQ 
and went back the next day to clean up (no diesel leaks then). A week 
went by, I was out of town, during which time the leak developed while 
the boat was sitting at the dock. My questions are numerous. How could 
this happen? Has anyone else experienced a sudden tank leak? Should I 
contact Catalina and see if they warranty such a failure? Can tanks be 
fixed or do I need to get a new one. How do I clean the area from the 
tank to the bilge which is somewhat inaccessible? Any and all advice 
would be greatly appreciated. One last thing, what cleaning product 
works best on diesel fuel.

Ken Danko
Grace
#802