Replacing fuel fill line in Osprey 200

[doug mayer]

Replacing fuel fill line from deck plate starboard side down to new fuel tank seems jinxed.  Cannot move old (30 years) fuel hose through the stringer(?) in either direction--up toward the starboard deck or back into the coffin.  How have other addressed this problem?

Am thinking of running the fuel fill hose up the front of the console (where bait tank was) to a fill directly under the bench seat--and constructing some glass to hold it in place.  Also thinking about hose to hose nipples to use the old immovable hose and connect new hose where we can--though I don't much like that idea.

Comments and suggestions hoped for.

[Bencarpenter112]

If your old line is immovable than i would guess its not in the best shape either. Im assuming that is also not accessible through your hatch. Could be the hose clamp is in place. you might have to remove the gas tank cover to replace the whole fuel line. The more cuts or nipple clamp off you have the more room for air to enter the system and possible engine problems. I just went through this but i was lucky enough to have the boat completely apart when I did it.

[RickK]

I think you'll find it's been foamed and is going to take some persistent twisting and pulling and some choice words thrown in.

[Capt. Bob]

While I don't recall a model specific on this, here's some thoughts and ideas on what you may be up against.

This is a long thread but has some good info:
https://classicaquasport.com/smf/index.php?topic=6789.msg48839#msg48839

Another idea:
https://classicaquasport.com/smf/index.php?topic=9956.msg87432#msg87432

These of course follow a tank replacement so the coffins are wide open and the members are either adding access via a deck plate or removing a portion of the deck/gunnel.

On a personal note, I re-routed my fill hose when I replaced the tank on my CCP. It ended up with the fill exiting the side of the console. It was a pain to fill because of the mount (spillage) and IMHO a mistake. Still, it was a lot easier to install than digging out foam and cursing repeatedly, though I like cursing.

Good luck.

[doug mayer]

Woot Woot.   Turns out fuel fill hose (1.5") was pinched tween inner and outer hulls.  It was 30 years hard, and so it simply bent over and freed itself when pushed.  New hose went in easily.  Bow light wires now run through the coffin, along with fuel sending wires, and static ground for fuel fill.  I will put some fuel in it to make sure nothing leaks, then put the coffin lid back on.  Woot woot!

[RickK]

Nice!