diesel fuel tank removal and repair

[Denny23837]

The original aluminum fuel tank on my 1984 Catalina has developed a leak. It appears to be a seam leak on the bottom of the tank. I'm looking for helpful hints as to how to remove the tank for repair or replacement. At first I though the job was going to be rather straightforward, adequate space all that sort of thing but it looks like there is a flange on the tank that is both screwed to and bonded to the bottom board that supports the tank. I'm hoping someone has done this before and can tell me how to break the bond and remove the tank.

Any suggestions on where to get a replacement tank. I checked the Defender catalog but they don't have a tank of the same measurements.

Thanks
Denny

 

[txtowman]

unless it is corroded you can have it repaired by a reputable welding shop.

 

[Don Guillette]

The easiest way is to have the tank fabricated to match the one you have now. The cost is about the same as buying a new one. My boat was at Shoreline Marina in Long Beach when the tank started leaking and I had the new tank built in Costa Mesa. The tanks only last about 10 to 12 years and that's it. I thought the leak was at one corner, which it was, but when they pressure tested it I had pin hole leaks all over the place.

On removing the tank _ mine was held in palce by 4 phillip head screws. Three came out very easily. The 4th one was a bear and in the most difficult place to get to. That is the story of my life. To add to the problem I stripped the head in the process. When I replaced the tank I used hex head bolts. You have to do what you have to do to get it out. If it is bonded than just grind off the flanges and have them attached later when you repair the tank. If you do repair the tank it will only be a matter of time before you develop a leak somewhere else.

 

[Jack - La Paz Mx]

Simply call Catalina. I removed my '83 tank 3 times to have it purged and welded. Each time it was put back, I had small leaks. Finally I followed the welder's advice, used gasoline (thinner than diesel), placed upon newspapers, discovered many pinhole leaks. The water layer at the bottom and algae eat through the aluminum. Called Catalina, tank for my '83 was in stock, fit perfectly. The new tank was also of a thicker gauge aluminum. Cost was very reasonable and no problems fitting it in (exact fit). I now suck the bottom layer of possible crud from the tank's bottom each season. Seriously, call Catalina, take advantage that they are still making boats and have the parts and expertise.

 

[GreenLight]

I just replaced my fuel tank last summer. As Don says, above, just 4 screws to take out and the last one (port side aft) is a dog to get at. I had to pull the drawers out of one of the galley cabinets to get at it.
The other problem was getting all of the old fuel out which you have to do before you can move the tank. The guy from my local marina had a vacumn tank that sucked it out.
Fortunately there was a label on the old tank with a manufacturer's name and part number on it and once I called them they were very helpful and made me a new one and shipped it in about 2 weeks. I recall that it cost about $400.