Hunter 40.5 - how do you remove fuel tank

Oct 26, 2010
2,161
Hunter 40.5 Beaufort, SC
1994 Hunter 40.5

I am doing some work on the rear berth area and have removed the aft bulkhead and am going to replace it.

My fuel tank is original (9/93) and only .09 inches thick. I understand there have been some historic problems with these tanks. With the bulkhead out it will come forward over the berth, but the tank is 16 inches wide and the door frame is less than 16 inches. I'd have to take the door frame off to get it through the door and out through the galley. It looks like its designed to come out through the lazarette (up). Is that the normal way to get it out? Any tricks to this? I already have every thing cleared to come out the lazarette or out the galley (except removing the door frame).

Also does anyone know of a replacement tank for these. I have tried to call Ezell in Perry Florida but they have an old message saying they will open on January 5, 2015 but no one answers the phone and the message has not been updated as of January 30th. Does anybody else make these tanks and what are acceptable materials of construction? I understood Ezell was still making these tanks and were now using thicker aluminum for construction. I won't know for sure if I need to replace the tank until I remove and can really clean and inspect it but I'm lining up alternatives.

Thanks in advance.
 

Rick D

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Jun 14, 2008
7,188
Hunter Legend 40.5 Shoreline Marina Long Beach CA
From my memory of prior posts, they came out the top. Any good tank manufacturer should be able to duplicate it; check around near a large airport. Good luck and let us know.
 
Feb 10, 2004
4,154
Hunter 40.5 Warwick, RI
Dan,

I always thought that it came out the lazarette, but that is not from personal experience.

What is the source of info that these tanks develop problems?

Please take lots of pictures of the process.

No clue on Ezelll. You should be able to get a copy of the engineering drawing of this tank from Hunter. I would look for a tank made from monel (stainless steel). I have been told that a stainless tank is best for diesel.
 
May 22, 2011
9
hunter 410 Coffs Harbour (Australia)
Hi not sure if I can help but are they similar to the 410 lay out. If yes, I had to cut the base out of the tank to get it out through the cabin door. We then measured up and rewelded 3mm plate in the base in the cabin. "Messy but it worked"We left 100mm clearance and welded stands/feet to the base so it could breath under neat. To prevent sweating of the metal and any fuel laying under the tank from spills.
 
Jun 8, 2004
50
Hunter Legend 40.5 Rock Creek
Hello,
I have replaced the floorboards in the port side lazarerette when I converted from CNG to propane. After seeing the tank below without the floorboards it seems that removal through that opening is possible. I have not removed the tank though and cannot say for sure that it would work. I would, however, start there. I have enclosed a photo
 

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