[C320-list] Fuel tank replacement, just do it!

[Ferris Wills via C320-list]

Hello All,

I know much has been written about replacing the fuel tank on the C320 and I thank all contributors who've previously documented/commented on that job. I’m nearly done with the project on Argo (‘98 #505) and their guidance made it a fairly straightforward task.

However, I foolishly ignored the wisdom of the ancients and waited until the OEM tank failed. Big mistake!

Arriving to the boat after a couple of week’s absence, I encountered a strong smell of diesel, something that had never occurred previously -opened the bilge to find an inch of standing diesel. Wow, what a mess! Luckily the bilge pump hadn’t started to push it overboard or I would’ve been in big trouble with the marina and SF Bay authorities. The clean up effort was horrible, and there’s still a faint whiff of diesel in the cabin 😵‍💫

I highly recommend replacing your tank proactively if it’s more than 20 years old. The downside of waiting until it fails can be huge.

Thx,
Ferris

Typos by iPhone

[Bill Allen via C320-list]

I've just started exploring this idea (1998 #536....) after reading many of the members' stories. Probably "on borrowed time" given the boat's age. Minor(?) point/question: Does there seem to be any correlation between the tanks failing and the use of the boat in salt vs. fresh water, and the fact that we northern Midwest folks (e.g. Michigan) only have the boat in the water for 5 to 5 1/2 months at a time? Given that I'm moving towards adding A/C on top of the tank location, I'm likely doing this upgrade regardless. Are the failures corrosion? Weld breaks?

Other question is that it appears that Ezell Industries is the manufacturer whether it's purchased from Catalina Direct or directly from Ezell. Are all the new tanks thicker than the originals (my understanding is that the originals are 1/16" thick and the newer ones, at least from CD, are 1/8" thick) regardless from which vendor you purchase it, and, are there any savings with purchasing directly from Ezell? Conversely, while I do think Catalina Direct people are swell folks, is there any other advantage to purchasing these tanks from them?

Best,

Bill Allen
Pegasus (1998 #536)
Northport/Grand Rapids, Michigan

[Ferris Wills via C320-list]

I verified that it’s the same tank (dimensions, material, fittings, sender, etc), but CD is a reseller and has them in stock. Ordering from Ezell means you wait a few weeks for them to build one for you.

I ordered directly from Ezell as it was a considerable savings for me. I’d like support CD but I find their prices and shipping to be too high.

Ferris
Typos by iPhone

> On Sep 17, 2025, at 2:59 PM, BA1...@comcast.net wrote:
>
> I've just started exploring this idea (1998 #536....) after reading many of the members' stories. Probably "on borrowed time" given the boat's age. Minor(?) point/question: Does there seem to be any correlation between the tanks failing and the use of the boat in salt vs. fresh water, and the fact that we northern Midwest folks (e.g. Michigan) only have the boat in the water for 5 to 5 1/2 months at a time? Given that I'm moving towards adding A/C on top of the tank location, I'm likely doing this upgrade regardless. Are the failures corrosion? Weld breaks?

[Diane Fowler via C320-list]

How much does a new tank cost?

Captain Diane Fowler, CRS, GRI, e-PRO

Entrepreneur / REALTOR®
Experience Real Estate Group, LLC
[1]https://dianefowler.eresuccess.com

Cell/Text: (239) 850-4935
[2]dian...@aol.com
"A referral of your friend is the greatest compliment anyone can give
me."

On Sep 17, 2025, at 9:14 PM, Ferris Wills via C320-list
<c320...@lists.catalina320.com> wrote:

I verified that it’s the same tank (dimensions, material, fittings,

References

1. https://dianefowler.eresuccess.com/
2. mailto:dian...@aol.com

[Karl Mielenhausen via C320-list]

Mine was $815 from Ezell last October. I opted for the inspection port
which added $125 to the base price of $690..
They all come with a new sending unit.
Mine took 17 days to fab and ship from FL to NC.
Shipping and tax added another $150.

Karl

[Tong Yi via C320-list]

Just as a curiosity. The tanks fail from moisture on the outside?

Tony G.
787 teachers pet.
Pine Beach, NJ

[Laura Gwinn via C320-list]

Another Q: Are there any “clues” or do they just fail? Do they fall
apart? What occurs?

Sent from Gmail Mobile

[Diane Fowler via C320-list]

I asked hubby same question!

Captain Diane Fowler, CRS, GRI, e-PRO

Entrepreneur / REALTOR®
Experience Real Estate Group, LLC
[1]https://dianefowler.eresuccess.com

Cell/Text: (239) 850-4935
[2]dian...@aol.com
"A referral of your friend is the greatest compliment anyone can give
me."

On Sep 18, 2025, at 8:40 AM, Laura Gwinn via C320-list
<c320...@lists.catalina320.com> wrote:

Another Q: Are there any “clues” or do they just fail? Do they

[Jack Brennan via C320-list]

That's an excellent question.

I have a 1998 with original holding and fuel tanks. Neither has given any indication of impending problems. I believe they are made of the same metal. Aluminum? Water, either salt or fresh, should not be enough to cause corrosion on its own. I would think any bad welds would have given way long before now. Both of my tanks are dry on the outside.

It's difficult to justify spending a couple of thousand on new tanks without having problems. If I did replace the fuel, I would probably buy a Moeller poly tank for about half the price. The big advantage is that they are indestructible, and you can see the fuel level to backstop your gauge. The holding tank might need to be CD due to its unusual shape.

I had an aluminum tank go bad on a Bristol 30 I owned. Turned out the PO had installed it abutting a stainless steel bolt. The stuffing box was hard to maintain due to its location, so saltwater regularly splashed the two dissimilar metals that were touching. That was where the hole developed.

Jack Brennan
Sonas, 1998 Catalina 320
Tierra Verde, Fl.









________________________________
From: C320-list <c320-lis...@lists.catalina320.com> on behalf of Laura Gwinn via C320-list <c320...@lists.catalina320.com>
Sent: Thursday, September 18, 2025 9:39 AM
To: C320...@catalina320.com <C320...@catalina320.com>
Cc: Laura Gwinn <laura.g...@gmail.com>
Subject: Re: [C320-list] Fuel tank replacement, just do it!

[Michael Deslauriers via C320-list]

My tank started leaking a small amount out from the bottom of the tank. I
could smell the diesel and once I put an absorption pad at the lowest
corner of the tank I was able to see the diesel color on the pad after a
couple days. I did also buy direct from the manufacturer and saved a few
hundred dollars back in 2020. Here is the drawing they sent me
<https://drive.google.com/file/d/1N35uoBSA4TWxpTfL7AprIo-s7H1sLvan/view?usp=sharing>.
Be sure to let them know the fuel line size so they can give you the
correct shutoffs.( I believe they gave me 3/8" and I needed 5/16" or vice
versa). Once I pulled the old tank out and looked for the leak I could
only find a penny size area that was discolored. When I pushed on the spot
with a screwdriver, it easily went through and it would have become a major
leak. I am glad I changed it before the major leak happened. Finally, I
inspected the entire interior of the tank and that was the only soft spot.

Mike Deslauriers
Gloria(2000 #717)
East Greenwich, RI

[KEN GEIGER via C320-list]

Some years ago, more than 10, a friend had an 80's something Catalina 30 that sprung a leak on the corner weld.  It was a saltwater boat turned fresh water.  They removed the tank and re -welded the corner and it is still working well today.
Ken GeigerNorthern Dream #765 2000

[Ferris Wills via C320-list]

Hi,

I had no indication of any problems until it failed. It seems the fuel tank fails from either inside the tank (pin holes) or outside anywhere a stray bit of metal (bolt, flake of metal) wedges against the bottom or side.

Search the list for lots more detail on how they fail, different options, how to do the job, etc. Much has been written on the topic.

I had the same inclination on my 1998; no signs of an issue despite regular inspection, and then it suddenly started leaking. A cautionary tale 😂

Ferris

Typos by iPhone

> On Sep 18, 2025, at 7:29 AM, Jack Brennan via C320-list <c320...@lists.catalina320.com> wrote:
>
> 

[Mark Seyler via C320-list]

I relaced the fuel tank on my 1995 #232 in November 2023. It was weeping a very small amount of diesel from the lowest point (the forward, inboard corner of the tank). In my case I believe the culprit was water in the tank (combination of condensation and water leaking in through a worn o-ring on the deck fill). As others have said, buying the tank from Ezell was less expensive than Catalina Direct, and they were easy to deal with. I chose not to get an inspection port because my air conditioner is mounted on a shelf over the fuel tank, and I wouldn't have been able to access the port anyway. That also saved me a few dollars compared to the Catalina Direct price.

On my boat the holding tank is plastic, so it's not a concern for failure due to corrosion over time. Nevertheless, I replaced mine earlier this year after I found a pool of green sludge underneath the tank. I ordered a new one from Ronco Plastics, which made the original, and was less expensive than Catalina Direct. The replacement was comparatively easy. Cleaning out the sludge that got underneath my shallow bilge pan was not.

Mark Seyler
S/V Reality,
Catalina 320, #232
New Orleans, LA

-----Original Message-----
From: C320-list <c320-lis...@lists.catalina320.com> On Behalf Of Michael Deslauriers via C320-list
Sent: Thursday, September 18, 2025 9:52 AM
To: C320...@catalina320.com
Cc: Michael Deslauriers <mdeslaur...@gmail.com>
Subject: Re: [C320-list] Fuel tank replacement, just do it!

[Dave Hupe via C320-list]

And I have a 1994 with original fuel tank and no indication of a problem. We are fresh water.   However, a buddy here with a 2005 C320 had a leak and replaced his. Go figure ......
Dave  Hupe
1994 C320 #32
Holland MI 

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