[C320-list] Fuel Tank Leak

[Bruce Heyman]

Anyone have some words of wisdom for removing a weeping 12 year old fuel tank?
Thanks,
Bruce
Somerset 2000 currently in San Diego

Bruce Heyman
949 289-8400

[Jon Vez]

Bruce,
Not a difficult job. Remove as much fuel as possible. I used an oil transfer pump inserted in the gauge port. Remove the hoses and tape off with plastic. Seal the openings on the tank.
The only way to remove the tank from the boat is through the aft cabin hatch. Remove the teak trim piece and the tank comes out pretty easily. Bought a new one from Catalina, but it did not come with new fittings.
The only problem I had with this project was breaking the old fittings when trying to remove them from the old tank. I was able to procure new aluminum fittings from the tank manufacturer, which is stamped on the new tank. Hope this helps and if you need additional specifics, just let me know...

Regards,
Jon

Sent from my iPad

[Bruce Heyman]

Jon,
Thanks! I'm finding it quite difficult. As we have a 16 AC on the shelf
above the tank we are not able to remove the shelf. It would appear that
the shelf needs to be removed or there is not enough clearance to slide the
tank back and out of its bed.
Thanks,
Bruce
Somerset #671

[Jon Vez]

Bruce,
I did remove the shelf to remove the tank, not sure you could do it any other way...

Sent from my iPad

[Rick Sulewski]

Jon,
Could you address a few questions surrounding your tank replacement? What is
your hull number, boat model year and the year you replaced your tank? Did
you determine the root cause for the tank needing to be replaced (for
example, boating environment -salt or fresh water), or was the replacement
necessary due to tank damage (exterior chaffing, inferior or poor tank
quality such as weak welds)? Just curious since some of us have some older
models and may learn what to look for or avoid. Also curious if anyone is
aware if Catalina ever addressed weeping fuel tanks as a preventative
maintenance issue or a manufacturing problem for the 320, or any other
models? Could a fuel tank leakage problem represent more than a random issue
if there are other owners out there who also experienced fuel tank leakage
problems....?
Thanks.
Rick
My-Ria Hull #277 1995 C320

-----Original Message-----
From: c320-lis...@lists.catalina320.com
[mailto:c320-lis...@lists.catalina320.com] On Behalf Of Jon Vez
Sent: Sunday, November 18, 2012 10:34 AM
To: C320...@Catalina320.com
Subject: Re: [C320-list] Fuel Tank Leak

[Jon Vez]

Rick,
I had a '99, hull #582. I no longer have the boat as I traded it for a 355. The problem was with a seam that began to weep after about 10 seasons. In doing some research, I learned a few things. First, according to many experts (Calder, D'Antoni et al), Aluminum tanks have a life span of 8-10 years, so not that unusual. However I noted that the new tank had a thicker wall structure. Not sure how relevant this is since my problem was with the seam. I also noted that the way the factory padded the bottom of the tank to prevent chafing was not great. Overall my tank was in very good condition when I replaced. No moisture, signs of corrosion etc.
The way I detected the leak was initially the faint smell of fuel in the aft cabin, and when I isolated the area, i found very little fuel accumulating forward of the tank, near the water tank. I put a few paper towels in that area to confirm it was not the Racor or hoses. Hope this helps...

Regards,

Jon

Sent from my iPad

[Bruce Heyman]

Jon,
Thanks. I'm going to try as to remove the shelf I would have to remove the compressor and air handler and the reinstall and recharge. I'm going to see if I can cut out the tank frame and then glass in a new one after repairing the tank.
Best,
Bruce
#671 Somerset

Bruce Heyman
949 289-8400

Jon Vez <Jon...@comcast.net> wrote:

>Bruce,
>I did remove the shelf to remove the tank, not sure you could do it any other way...
>

>Sent from my iPad
>

>On Nov 18, 2012, at 12:20 PM, "Bruce Heyman" <bruce...@cox.net> wrote:
>
>> Jon,
>> Thanks! I'm finding it quite difficult. As we have a 16 AC on the shelf
>> above the tank we are not able to remove the shelf. It would appear that
>> the shelf needs to be removed or there is not enough clearance to slide the
>> tank back and out of its bed.
>> Thanks,
>> Bruce
>> Somerset #671
>>

[Bruce Heyman]

Jon,
The tank is out but it required many pages out of the profanasaurus. Was able to partially remove the AC compressor and air handler so that I could get at least part of the shelf out. Thanks for the tip on bringing it out through the aft cabin. I thought that access door was not always on our boats. Wonder how you would get the tank out without that door.

I'm going to pressurize the tank and see if I can find where the weld is leaking and get it repaired. The tank seems to be in really good shape otherwise. I will also get it steam cleaned to remove any sludge that has built up on the bottom.

Did you replace the fuel gauge sender?

Again, thanks for your advice!
Best,
Bruce
Somerset 671 San Diego (normal Dana Point)

[Jon Vez]

Bruce,

Glad to hear you managed to get around that shelf. I have a feeling that aft cabin hatch is made to remove the tank, because it definitely won't fit through the aft Lazarette--that's where my profanity laden diatribe came when I attempted this project!
A new sender came with the new tank, so I saved the old one as a spare. If you have someone that is capable of repairing the leak then that is certainly an option. As I mentioned, the new thank is made of a thicker guage aluminum, but that is the only difference. I believe I paid about $450 including shipping for my new one.
When you put it back in, make sure those rubber chafe protectors are properly placed. Mine were attached with duct tape. I was going to put a neoprene pad under the new one, but I didn't bother because you need to make sure air circulates under the tank so there is no chance of condensation creating corrosion etc.

[Jeff Hare]

For people who have found leaks, was it obvious which direction the cause of the leak originated? Ie: from the inside of the tank out due to something in the fuel, or the outside in?

I've also wondered whether it makes sense to have the tank exterior cleaned, primed and painted with an epoxy based paint then some rubberized spray undercoating for the areas that might contact the supports. I'm always suspect of stray screws or metal shavings etc., wedging up against the fuel tank and corroding. Also might seem worthwhile to ensure that the tank is raised slightly above the hull (if it isn't already) so that seawater doesn't sit in contact with the tank anywhere.

I think Steve Dashew commented once that metal boat owners fear a dropped coin finding its way into the bilge. I've been considering a pre-emptive strike against a fuel tank leak this since our hull is now going on its 12th season. I thought I saw signs of something oily in the bilge. I think I have a new spring project.....

-Jeff

[Ken Danko]

I replaced my tank two years ago. The leak was on a seam. From what I
have read, plastic tanks have a longer life but I couldn't find a
plastic replacement that would fit in the same space. I discovered the
leak when the bilge was suddenly full of fuel. The cleanup was a very
big and messy job which suggests that doing something preemptive, either
replacement or coating with epoxy, makes sense.

BTW, it took me months to get a replacement tank from Catalina. It might
be faster to go directly to the tank manufacturer.

Ken

[wfl...@aim.com]

Bruce,
Your AC setup sounds like mine. It really looks crammed in there. How hard was it to remove and then replace yours?


I think I need to top off the freon because my evaporator coil frequently ices over but I cannot see any place to attach the refill hose and from others I have talked too, it can cost a lot to have a professional do the work.

If removing the unit is not really complicated, I thought I'd take it to someone rather than paying for a "house call". My marina can't do this and the guy they send in is really pricey plus the marina adds a substantial lug onto his invoice.

Thanks
Bill

[Jon Vez]

Jeff,

Any fuel from a leak will flow forward of the tank, towards the bilge. The slope of the hull moves any fuel towards midship. One place to look for early leakage is at the rudder stringer. That area has a little 'pocket' where fuel will accumulate.

The tank is set on a couple rubber stringers taped vertically to bottom of the tank. This keeps it off the bottom of the hull.
Not sure if encapsulating aluminum is a good idea due to natural temp fluctuation creating moisture on the aluminum. If encapsulated, that moisture may get trapped--not sure though.
Good point on any metal touching the tank. PS did a test where it took about a week for a copper penny to eat through a tank when they introduced damp salt water around the penny...

Sent from my iPad

[Donald Lawson]

All
I think I saw a 28 gallon replacement tank for the 320 on the Catalina Direct Website? Might not be an option for those with AC above the tank.
Don #1005