Fuel Tank Replacement

[Paul and Judy]

Anyone have experience cutting out a bulkhead to get at a fuel tank? My 1993 Hunter 33.5 has sprung a leak and needs to be replaced. I hate the thought of cutting the bulkhead in the rear stateroom to access the tank. If I could avoid that it would be great. Anyone have any thoughts on an alternative means to fix this 21 Gallon Aluminum diesel fuel tank.
Regards
Paul

 

[ggrizzard]

P & J, Tho I don't have your boat, I encountered a similar problem on my 1979 H30C. On my boat the quarter berth lies adjacent to the tank in the engine bay.
I was able to remove the plywood/veneer bulkhead in one piece. I could have reinstalled it but as it was water damaged, I made a new one. If It is wood there will be many screws, some or all hidden behind plugs, and some structural members behind the panel. Don't lose any of the pieces and label them as you remove them. Put screws in marked pill bags (Walgreens) or small ziplocks. You can figure out how I know to do that.
So, is your 'Bulkhead' FRP or wood? If it's fiberglass it might seem a pill but it's doable and the cuts can be refinished like new.

Good luck.
G.

 

[Paul and Judy]

G.
The bulkhead is FRP. In my boat the rear berth runs port to starboard and the wall aft is all FRP. I figure if I cut a few pilot holes from the Tank side (where i have minimal access) I could then cut an opening large enough to get the tank out and install a new one. Hunter provided me with the OEM tank manufacturer and a drawing. They would make another tank for me for $325.00 plus shipping. I have been reading WEST SYSTEM Fiberglass boat repair and maintenance manual and have a good idea on how all that FRP repair works. Do you have any pictures on how you did your project? I plan to document my project in order to share all my nightmares. Thanks for your input.
Paul

 

[ggrizzard]

I was up to my ears in sawdust and varnish so no pics,sorry.