40.5 Fuel Tank Replacement

Jun 13, 2004
90
Hunter 40.5 Hampton,Virginia
Well after 23 years the fuel tank in Island Girl started weeping diesel fuel. After quickly removing 40 gallons of fuel so not to have an environmental disaster, I contacted Ezell in Florida and ordered an exact duplicate replacement tank. Delivery was about 2 1/2 weeks and the new thicker tank looked GREAT ! Next was to establish a plan for installation. Unfortunately for me I had to remove a 6KW generator to gain access to the fuel tank. So after unhooking everything for removal I rafted my boat along side of my friends 48 Kady Krogan and used his electric dingy hoist to lift and move the genset aside in the cockpit. With the generator out of the way removing the platform above the fuel tank was easy. Once the fuel lines were removed and the tank unbolted from the floor we were able to lift, tilt and remove the tank from the lazarette easily. The install was just as easy. Also wanted to mention that the new fuel tank is now .125 thick rather than the original .090 and comes with a Wema fuel sending unit installed.
If anyone has any questions please feel free to contact me at mwg51@cox.net.
 
Feb 10, 2004
4,153
Hunter 40.5 Warwick, RI
Did you take pictures? Our h40.5 is 19 years old. It sounds like the failure was without any warning.
 
Jun 13, 2004
90
Hunter 40.5 Hampton,Virginia
I have a few pics but they are not real good. I will upload them soon. What I did to check for a leak was to put a white oil obsorbent pad in the approximately 2 1/2 space between the forward section of the tank and the aft bunk wall at the aft berth drop down panel. In the colder months it helps to collect condensation moisture as well as diesel if it starts weeping. Mine started to weep when I had a full tank due to the extra fluid weight.