Replaced Fuel Tank Hunter 40.5 completed with pics

[smokey73]

I replaced the fuel tank in my 1994 (produced late 1993) 40.5. I didn't have a known leak but based on other info it seemed it was time to replace it because it will leak soon. Boy was I right!!

It came easily out the top of the port lazarette single handedly. I was surprised how easily it lifted. I'm sorry I didn't get any pictures of that but since I was by myself I couldn't lift the tank and take a picture. Here are some pictures of the old tank and the new tank.

The bottom had corrosion that had not obviously been leaking but when I probed the spots the pick went through like it was going through wet cardboard. There we several places that would be leaking very soon if they were not already weeping.

Now that the tank is out if somebody is handy with Aluminum work they are welcome to have it free, otherwise it goes to recycling if they will take it or to the trash. The bottom will have to be cut out and a new bottom welded in place. Shipping would be vary by location. $169 to Jacksonville, FL, $217 to San Diego UPS ground. It would cost maybe $25 to package it so total all in cost would be the packaging and the actual cost of shipping.

Here are the pictures

 

[JimR]

With what?

Please tell us what you replaced your fuel tank with. Custom or off-the-shelf?
That tank is a wake up call to all us owner of boats of the same era.

Jim R

 

[smokey73]

Replaced with a tank from original manufacturer

Please tell us what you replaced your fuel tank with. Custom or off-the-shelf?
That tank is a wake up call to all us owner of boats of the same era.

Jim R

Jim,

I replaced the tank with an Aluminum tank from the original manufacturer, Ezell. They are in Perry Florida and are still in business. They are making the tanks from thicker 0.125 in aluminum and had the original drawings. The original was .09 in. They customized it a little by putting in two clean out openings and 3 pick ups and 3 returns. (Yanmar propulsion, Nextgen 5.5kw generator, and a future fuel polishing system). I figured with the thicker Al it should be good for 20 to 30 years, especially if I keep it clean inside. I didn't want to sacrifice size for a tank that did not fit in the space efficiently.

I have no affiliation with Ezell, but they are great people and the price, while not cheap, was much less than other quotes and frankly, less than I expected. I am very pleased with the whole process.

Yes, people with boats of our vintage need to be very attentive to the Aluminum tanks. If you wait for the leak you may be faced with a huge EPA fine if it gives way when you are not there and the automatic bilge pump kicks in and pumps it overboard. The fines and cleanup costs will be huge and I doubt if Insurance (even Boat US) will pay for a maintenance issue that spills fuel, though I don't know for sure.

Dan

 

[Jeff]

When i replaced my leaking tank a couple of years ago Ezell was quite helpful. Great customer service. They still had my original drawings as well.

 

[Rick D]

Moderator

Any chance of getting this over to the 40.5 section?

 

[smokey73]

I'd be happy to - but what is the 40.5 section?

Any chance of getting this over to the 40.5 section?

Rick - I'd be happy to but what is the 40.5 section? Do you mean the 40.5 Boat Info section? I wish I'd have taken some more pictures but since I did it my myself no one was there to take the pictures of pulling it out and putting it back in. The longest part was siphoning out the fuel to get it down to a manageable weight. I got all but about a quart or two out I think since it wasn't much heaver than the new tank.

Dan

 

[Rick D]

Re: I'd be happy to - but what is the 40.5 section?

Smokey, yes, the Boat's section. Not sure if you can do it yourself, but maybe you can cut-paste the narrative and photos. This is good enough info that it ought to have a place there permanently.

 

[smokey73]

Will do

Smokey, yes, the Boat's section. Not sure if you can do it yourself, but maybe you can cut-paste the narrative and photos. This is good enough info that it ought to have a place there permanently.

Rick, Will do when I get some time. I may have a few more pictures too.

Dan

 

[Michael G]

Smokey, If you don't mind saying what was the cost of the new tank from Ezell in Florida?