Replacing fuel tank on Hunter 35.5

[tjar]

Has anybody tried to replace the fuel tank on a Hunter 35.5? The old tank has been professionally cleaned twice and the fuel polished, but I'm still picking up gunk in the filter. I'm starting to believe that the most effective solution is to replace the tank and I'm wondering how hard it is to get the polyethylene tank out and install a new one?

For ultimate reliability, I'm also considering installing a Parker FPM fuel polishing module to keep the problem from recurring. I can get one for less than $500.

I already plan to replace the aluminum holding tank since it's 20 years old. I will cut a hole in the aft cabin bulkhead to get to that one, but it doesn't look like I can reach the fuel tank that way too.

Thanks for any tips about the best approach.

 

[Jeff]

tjar, you don't mention the year of your boat. I have a 1993 H33.5. I replaced my aluminum holding tank after 13 years. Wasn't leaking yet but "The Head Mistress" suggested a preventative measure was in order. I switched to a roto-molded plastic tank. As for the fuel tank, mine is aluminum. It started leaking after 20 years. Ours was located behind the bulkhead on the port side of the aft cabin. We had to cut a rather large access hole in the bulkhead to replace the tank. I carefully cut the panel so it could be reused and cover the cuts with teak trim. I stayed with an aluminum tank because the original manufacture (Ezell) still had drawings to remake the tank. They are using thicker material now. If I get another 20 years out of the new tank I'm happy.

 

[tjar]

My (soon to be) boat is a 1993 H35.5. The holding tank is aluminum and located in the same place as yours. I am also going the take "The Head Mistress" advice and replace this tank. I'm planning to install a large hatch in the bulkhead to retain the boat's watertight integrity yet still allow access to the area.
The fuel tank is polyethylene and is located between the aft lockers under the swim platform. It was cleaned twice (?) by the current owner, but we still experienced fuel starvation during the sea trial due to gunk in the pick up screen and a clogged filter. He has since had it flushed and cleaned again, all new filters, and new fuel.
I hope to take delivery next week and will evaluate the condition of the tank then. Hopefully, the problem has been corrected, but some forums advise that the only real solution is to either open the tank and manually scrub it, or replace it. For the cost of a plastic tank, it's probably easiest to replace.

 

[TommmD]

I have a '95 35.5 with the same tank, same location. Threads on the sender are stripped & fuel sloshes out when heeled. I can tell you, when you replace the pivvy tank & put a hatch in, that bulkhead still has plenty of openings.

At this point the only access I see is to cut thru the swim platform & re-glass it. Looking for alternatives now but there doesn't appear to be much. I just bought the boat last year & will chalk it up to "hidden purchase costs". I am otherwise very happy with the boat & would recommend it to anyone except out and out racers. Sails very nicely, very comfortable.

That poly tank will be aluminum soon. Anyone recommend what gauge that should be?

 

[woodster]

1/8" or better maybe 3/16" and put a baffle in the tank

 

[TommmD]

Thx .. good thought on the baffle.