1991 Pearson 31-2 aluminum fuel tank leaks. Replace with plastic??? Looking for advice. Will cost $300 to repair

Feb 13, 2023
28
Hunter 27-2 Milwaukee
Original capacity 16 gal. Can live with 10 or 12 gallons. Diesel engine requires a return to tank fitting as well as fill, vent and supply fittings
 
May 29, 2018
499
Canel 25 foot Shiogama, japan
If your leak is a pinhole, the tank is pretty well gone.
You will play wack-a-mole repairing the next hole.
If it is a cracked seam it is (maybe) repairable.
If repairable I would shop around for quotes. Welding a cracked seam is not a big job.

A new plastic tank would be my choice.
Check the net. You will find tanks cheaper than from a marine chandler.
The following link is for the tank only. Lid is extra!
1729811459989.jpeg


gary
 
Jan 4, 2006
7,012
Hunter 310 West Vancouver, B.C.
See post #3 by @Peggie Hall HeadMistress for lead to an endless selection of poly fuel tanks :


As mentioned by @garymalmgren , a plastic tank would also be my choice above any metal. Aluminum is probably the worst you can do.
 
Dec 2, 1997
8,868
- - LIttle Rock
Plastic tanks made to hold water and waste cannot be used to hold fuel...Petroleum products would saturate them. There are two different types of polyethylene...water and waste tanks are made of "linear" PE...petroleum products would saturate it. Plastic fuel tanks must be made of "cross linked" PE and also must be USCG approved, meeting several standards that include "no horizontal surface on which liquid can pool." and others. Because of that and liability risks, there are very few mfrs who makes plastic fuel tanks. Moeller is the only one I know of who still makes anything but small ones for outboard engines and theirs are expensive!

Aluminum is actually the recommended material for permanent marine fuel tanks because of its resistance to salt air that steel doesn't have. Do a search for aluminum FUEL tanks fitted for use with diesel.

--Peggie
 
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Likes: LloydB
Jan 11, 2014
12,273
Sabre 362 113 Fair Haven, NY
The two main causes of pin hole leaks in aluminum fuel tanks are bacterial growth inside the tank and moisture trapped between the tank and hold down straps.

Bacteria form colonies in the tank and sit on the floor. The by product of bacteria is acidic which gets trapped between the bacteria colony and the tank causing it to corrode and form pin hole leaks.

Tanks are often set on foam strips to allow for ventilation beneath the tank. The foam can retain moisture which accelerates corrosion. The better way is to glue fiberglass or plastic strips to the bottom of the tank to raise it.