[C320-list] Fuel Tank Replacement

[Jack Brennan]

Had an HPDE tank on a previous boat. Worked well. Big plus is you can see the fuel level. A minus was that the fittings to screw in the inspection plate weren't done properly. I had to use adhesive sealant to mount it. The tank tends to expand a little after it is first filled, so strap it firmly but not really tight.

Jack Brennan




Sent via the Samsung Galaxy A32 5G, an AT&T 5G smartphone



-------- Original message --------
From: Dennis Cookson via C320-list <c320-list at lists.catalina320.com>
Date: 10/29/23 12:23 PM (GMT-06:00)
To: "C320-List at catalina320.com" <C320-List at Catalina320.com>
Cc: Dennis Cookson <dennis at cooksons.net>
Subject: Re: [C320-list] Fuel Tank Replacement

I am in the process of replacing Catalina's 24-year old fuel tank as a precautionary measure, although on removal I may find that it already has a pinhole leak because there is occasionally a slight whiff of diesel in the aft cabin. It seems wise to do it before it becomes critical, especially as the boat is on the hard now for the winter season. I have Ezell's drawing for a replacement, although mine was made by Skyline Industries of Pleasant Grove. However, as I don’t live in the US, I’ve sought quotes from local fabricators here in the UK to manufacture a custom replacement because the cost of international shipping, VAT and customs make an import unattractive.

I’ve now received quotes from four fuel tank fabricators: two that make aluminium tanks and two that manufacture in 10mm thick plastic (HDPE).  In aluminium, the best quote has come in at £630 including VAT and shipping. That’s for a plug-in replacement in 3mm thick 5083 marine grade aluminium including all the hosetails, sender cutout, an inspection hatch, internal baffle and leak testing.

Interestingly, a custom HDPE tank is not much more expensive, and has a few advantages including complete resistance to corrosion, reduced condensation, and ease of installation. It comes with an inspection hatch, sender cutout, internal baffle, and a number of BSP threaded sockets into which elbow hosetails  in plastic or brass can easily be fitted. I estimate that a complete plug-in replacement for the existing tank would work out at around £720.

Having removed the shelf above the tank my next step is to pump out its contents and then extricate the empty tank, following which I’ll be double-checking dimensions and support to ensure a good fit. I’m seriously considering choosing an HDPE replacement, and would welcome comments from owners who have taken this route, or considered and rejected it for good reason.

Dennis Cookson
‘Catalina’  #577



> On 29 Oct 2023, at 15:17, Bruce Heyman via C320-list <c320-list at lists.catalina320.com> wrote:
>
> Hi Dan,
> Unfortunately one day you will open the boat up to the aroma of diesel.  You will look in the bilge and find that the tank is weeping into the bilge.   The original tanks were 0.087 inch thick and I think the new one that I replaced ours with was 0.125.   That should add some robustness to the design.   Doing everything you can to keep water from remaining stagnate inside the tank will help immensely.  Also, need to make sure nothing is in contact on the outside of the tank that can cause galvanic corrosion or hold moisture against the surface.
>
> Bruce Heyman
> Somerset #671   San Pedro (LA) California
>
> -----Original Message-----
> From: C320-list <c320-list-bounces at lists.catalina320.com> On Behalf Of Dan via C320-list
> Sent: Friday, October 27, 2023 5:57 PM
> To: C320-List at catalina320.com
> Cc: Dan <danb70341 at gmail.com>; ROBERT MILLER <r.miller at shaw.ca>
> Subject: Re: [C320-list] Fuel Tank Replacement
>
> How do you know when time to change tank?
> #250
>
> Sent from my iPhone
>
>> On Oct 27, 2023, at 4:54 PM, ROBERT MILLER via C320-list <c320-list at lists.catalina320.com> wrote:
>>
>> Replaced my tank 3 years ago. Dealt with Ezell direct, and it was seamless, even with delivery to Canada. They provided drawings so I could check measurements,  and added a clean out/inspection port at my request for nominal cost. Perfect fit. There are detailed instructions on the Association website for this job, as well as a Mainsheet article.
>> Rob Miller
>> #571
>>
>>
>> Sent from my iPhone
>>
>>> On Oct 26, 2023, at 2:46 PM, Jeff Smith <svsailmates512 at gmail.com> wrote:
>>>
>>> I second that. I purchased a tank this spring, and the Ezell tank
>>> fit perfectly. I replaced all my fuel lines at the same time.
>>>
>>> Jeff
>>> ‘94, #121
>>>
>>>> On Thu, Oct 26, 2023 at 4:23 PM Jason Reynolds via C320-list <
>>>> c320-list at lists.catalina320.com> wrote:
>>>>
>>>> I replaced my fuel tank approximately 5 years ago and used ezell.
>>>> They were great!
>>>>
>>>> Jason
>>>>
>>>> Sent from my iPhone
>>>>
>>>>> On Oct 26, 2023, at 2:45 PM, Mark Seyler via C320-list <
>>>> c320-list at lists.catalina320.com> wrote:
>>>>>
>>>>> I need to replace the fuel tank on my 1995 No. 232, and was
>>>>> surprised
>>>> that
>>>>> Catalina Direct now charges over $1,000 for a new tank. Has anyone
>>>> found a
>>>>> less expensive source?
>>>>>
>>>>>
>>>>>
>>>>> I saw an exchange on the list back in February of this year that
>>>> mentioned
>>>>> getting a tank less expensively through Ezell, and/or through Jeff
>>>>> Hare
>>>> and
>>>>> Ezell for his re-designed, larger tank. Has anyone done that more
>>>> recently?
>>>>> I tried contacting Ezell, but so far they have not responded.
>>>>>
>>>>>
>>>>>
>>>>> Thanks in advance for any help anyone can provide.
>>>>>
>>>>>
>>>>>
>>>>> Mark Seyler
>>>>>
>>>>> S/V Reality,
>>>>>
>>>>> Catalina 320, #232
>>>>>
>>>>> New Orleans, LA
>>>>>
>>>>>
>>>>>
>>>>
>>>
>