Hunter 40.5 Fuel Tank Replace

[hun4449]

Last spring polished and had access port placed on fuel tank. While doing the work of scrubbing the tank the tech told me that there were some pits at the bottom of the tank and should replace tank in next year or two.


Well yesterday, while doing spring cleaning of the fuel tank area, found slight diesel fuel leak. Glad I started on port rear lazarett area as this could have become an much larger issue down the road. Pumped the tank out and now ready to pull the tank and replace. Searched forum for fuel tank under 40.5 in hopes of finding leads. No luck.

Anybody know where I could find tank for the 40.5.

Suggestions on going stock tank or plastic?

Has anyone replaced the fuel tank on 40.5. Looks like to tight fit getting tank out of the lazarette. Doe it come out through the top or do I have to pull the aft cabin bulkhead to remove the fuel tank?

The current tank has baffle built in. Do the plastic tanks come with baffle or can you order with baffle.

What a pain in the lester, Just getting ready for spring shake-down cruise.

Any all advice would be greatly appreciated.

 

[Rick D]

I think the tank is from the same manufacturer as the waste tank. The name on mine is on the top of the fuel tank. I think it is Ezell. Here is a link to the site. If it were me, I would go back with aluminum, but specify a heavier gauge. They probably have the spec's in-house. BTW, I'm pretty sure the bulkhead has to come out. Let us know what you do and take some pix! http://ezellindustriesinc.com/

 

[Rick D]

Just noticed that you are in SFO. There is likely a tank manufacturer locally who could weld in a new bottom. Check around airports since they do a lot of custom aluminum tank work.

 

[Rick D]

A Better Description Of Your Project

Follow this link to see what is in store. This owner replaced the aft water tank, but it's the same for the fuel tank it appears.

http://hunter.sailboatowners.com/in...d=267&cat_id=43&aid=7526&page=article&mn=40.5

 

[hun4449]

Thank Rick,

Pulling fuel tank tomorrow if all goes well. This is very helpful. Looks like it could come out from the top. Got my fingers and toes crossed.

I drafted longer reply and then got side tracked back to the tank area and forum timed out. More on the project soon.

All best,

Joe

 

[hun4449]

BTW... Might have something here... Channel #5 Diesel... Brad Pitt as ????

"Ahh Love the smell of Diesel in the Morning!"

 

[Jean Guy]

I pull mine out on My 40.5 a few year back to clean it. It come out fairly easy from the top. Just have to remove the board at the bottom of the lazaretto.
Good luck

 

[hun4449]

Thanks Jean Guy,

Pulled the boards at the bottom of the lazarett and it does look like fairly easy enough to remove the tank from top.

Called Ezell Industries (OEM) and they are looking for the drawings. Fortunately the ID plate is readable so got a good start.

 

[robertsapp]

If the pits are only on the bottom, any decent welding shop can cut out the bottom and weld in a new one. It should be much cheaper than a new tank.

 

[davidpackwood]

We have a 1996 Hunter 40.5 based in Cortez FL. We have removed the aluminium fuel tank from the boat and the pressure test found 2 pin holes. We now need to decide if we want to put in a new tank or repair the one we have. Can anyone suggest where in Florida we could get the tank repaired??
Also has anyone considered a plastic tank??
Many thanks for your help, David

 

[hun4449]

Hunter 40.5 fuel tank replacement, manufacturer (1995)

We have a 1996 Hunter 40.5 based in Cortez FL. We have removed the aluminium fuel tank from the boat and the pressure test found 2 pin holes. We now need to decide if we want to put in a new tank or repair the one we have. Can anyone suggest where in Florida we could get the tank repaired??
Also has anyone considered a plastic tank??
Many thanks for your help, David

Yes same issue with mine. Pin holes. I went to EZELL Industries, in Perry FL, the original manufacture of the aluminum tank. I had Ezell build new tank and add two inspection plates, increased the tank gauge size one size up from stock.

Contact Jamie art Ezell 850-578-2558... Jamie <ezellsales@gtcom.net>

See attached drawings. One with my modification with inspection plates added and other drawing Ezell stock. Also note that the stock tank has two fuel pick-ups and two return fittings. I removed one of each as not needed for my application, which helped reduce price a little. (probably extra fuel fittings where for GENSET)

Be sure to let Ezell know what size aluminum hose barb you will need. I have been trying to find local aluminum hose barbs to fit my tank - fuel hose without much luck. Been distracted with chasing boat dollars other projects and hope to order proper aluminum barbs from Ezell this week. Ezell does great work and the tank is work of art. ;-)

At suggestion from local yard, I did epoxy sealer on all exterior surfaces with exception of the top. Yard suggested doing the compete tank but I like to see the shiny top of tank. I expect with the epoxy coat, increase gauge of aluminum, that this tank should last 25 years. Original lasted 17 years.

One thing that does concern me with original Hunter tank design. "The tank is not strapped down." Working on a strap down system. Still scratching my head on that one. Original fuel tank was only held in place by two small tags on starboard bottom of tank with one small screw each tab, tab on forward bottom of tank with two screws and one tab aft with two small screws. Probably over engineering the mounting system of the fuel tank, but better safe than sorry.

 

[Rusty south]

Where do you gain access to the fuel tank? I have to change the fuel level sending unit on 1996 hunter 40.5 ?

 

[Stevew123]

We have a 1999 410 we had to remove the bulk head in the berth to gain access. We reweilded a 4mm checker plate floor into the tank and added small legs on the bottom of the tank to allow the metal to breath

 

[Marco Garcia]

Mine came strapped down thru the floor. See picture I used a nylon strap for the new tank. I also drilled a drain hole on the surface of the floor where is lower than the rest ( right of the strap hole).

Replaced the kick board with Marine teak faced Plywood.