22-2 CCP gas tank replacement

[GoneFission]

OK, got the project started today!  First had to remove the 5200 from the seams - utility knife cuts it, them pull it out...  



Then take out the screws and lift the console up with blocks underneath.  After the center panel comes out  you can see the tank.



The tank comes out - but AS did not make it easy - check out this clamp arrangement on the fill hose - note these hoses are steel reinforced, so you need a knife and wire cutters to cut the hose:



Several areas under the original foam padding are badly corroded.  Here's the real culprit:



The new tank from Phil at Alloy and the old tank:



Of course, nothing goes EXACTLY as expected...   The front of the tub is cracked, so there will be an additional glass repair required...  



Tomorrow is glass repair, trip to marine supply for new hoses, and new coat of varnish on teak that gets covered.  Tuesday is tank installation, caulking, fasteners back in, etc.   Lotsa gas (85 gal   ) and water test on Wednesday (I hope!!).

[RickK]

Looked nice and dry in there.  Nice job on the step-by-step.
After the gas part is the fun part

I might try to figure out a way to seal the hatches over my bilge/freshwater tank access in the aft of my 230. Most every bit of water that comes into the boat - rain or my using the hose goes right into the bilge via the seam and drains around the hatch.  Aquasport fixed that problem with a design change in the next years model.  I'll still need to open the small hatch to access the fill plate on the water tank but that will keep 90% of the water out anyway.  Have to think about the 5200 method OR get the sawzall out and make the same mod that Aquasport did.  I think Fishhead said he thought about duct tape to keep all the fish guts out of the channel.

Your project is looking good though.

[GoneFission]

It was not so dry for quite a while, as evidenced by the corrosion under all the foam padding.  I've epoxied my new tank, and will not be putting foam pads under it - they just create corrosion points.  I think I will foam the tank on the sides, use the existing hold-downs, and it should last for as long as the boat (hey, the original went 25 years!    ).  

Check out the corrosion under the foam 3 places were almost through-wall in addition to the one that went through:  





See ya on the water - hopefully on Wednesday!  

[LilRichard]

GF- You might use neoprene pads... they do not corrode aluminum.  Glue them to the tank with 5200... or foaming will work too.

[GoneFission]

It looks like the pads that were on the tank were neoprene.  I don't think it was material that corroded the tank - it was the moisture that the pads retained.  If you look at the old tank/new tank picture, it is clear that there was a water level about half way up the old tank.  That probably was not permanent, but the center cover was not well sealed and allowed water to collect in the tank tub.  Even when the tub drained, moisture was retained by the pads.  The sites of corrosion on the tank are all under the pads - and the pads are not rubber.  I would bet that my old tank would not be leaking today if those pads were not there - the rest of the tank looks good!  

My $0.02...

[LilRichard]

Well either way I doubt it will leak again anytime soon!

[jdupree]

Looks good    I noticed your tank setup is the same as mine.  I did cut and replace the filler hose that comes into the tub.  I wanted to replace the whole filler hose, but it looks like yours is the same as mine in that the other part of the filler hose runs under the deck and can't be accessed.  I hope mine holds up

Sorry about the tub being cracked and messed up :cry:   Don't you just love how one boat project ends up being 3 or 4

Let us know how it comes out.

[GoneFission]

When in doubt...



         

Now back to work!!!

[jdupree]

No Doubt :!:   Are you going to try to replace the filler hose under the deck?

[GoneFission]

Tank went in today - fits like a glove!   :)

Got the fuel hoses installed - man that stuff is $$$$!!!!  3/8" automotive fuel line is like $0.40 a foot - the marine stuff with the red stripe is like $2.00 a foot!!  
 

But hey, it's a boat - things are supposed to cost more...  

Photos later tonight or tomorrow!

[LilRichard]

Yeah, marine hose is very expensive.  I asked a guy at a specialty rubber place what the difference is... he said that the two are almost identical, one is just CG certified.  I bought the marine one to be safe.

Does anyone know if that is true?  Not advocating misuse of hoses, but I am very curious.

[GoneFission]

OK, progress continues - got the tank in, hoses hooked up, and first foam application:



Looking toward the bow, note I decided to use silicone hose rather than foam pads to insulate the straps from the tank - the hose will not retain moisture and is more durable:



Next the rest of the hookups are complete.  I have a cooler/livewell/swingback seat and decided to plumb the drain overboard at the same time:



Then screw down the center panel, drop the console back in place, and caulk everything!  White 4200 for console, Tan 5200 for deck seams (better match for the tan CCP deck color):



I had to cut a new through-hull for the overboard drain - it's amazing how heavy the Aquasport hull is - here is the core from the cut - over 1/2" of solid fiberglass!     No wimpy core or lightweight stuff here!



All that's left is final cleaning, hookup the tank gauge sender, reinstall the coffin, fill it up with gas, and see how it all works!  

See ya on the water - tomorrow!!  

[John Jones]

Good deal.  I know you are glad to be done with that.

[GoneFission]

Took her out off Cape Fear yesterday - what a beautiful day!!     The seas were calm, the sun was shining, and the fish were biting!  Caught spanish mackeral, bluefish, and flounder.  Missed a nice king mackeral, but hey - at least I was out there...   :)

BTW - The new tank holds 86 gallons - thanks again to Phil at Alloy Metal for his good work!  I am going to color this project done!  If anyone needs the specs for the AS 85 gallon fuel tank, I've got 'em.  

See ya on the water!

[The Bear]

awesome! a job well done!