1981 200ccp Fuel Tank Replacement

[WildBill20CCP]

Hello everyone! I am new to the site and was hoping for some help with my 20ccp. I am in the middle of replacing the 29gallon tank the previous owner had installed. The tank worked fine but really limited my range especially with a 200hp 2 stoke. After pulling the console, and lifting up the access panel, I found the tank to be resting on loose blocks of wood and secured with the metal straps over the top of the tank. The setup seemed extremely suspect so i am thinking of going with another poly tank and using the same metal straps only this time lining the bottom of the well with rubber mat material to provide a good base for the tank.

 The questions I'm hoping to answer are:
What tank dimensions will work for the fuel area? I would like to have at least 50gallons+

The well seems structurally strong but does flex a very small amount if I am standing directly in the middle of it. Is this normal?

The two fittings for the fill hose and vent hose seem to lead to solid molded in piping that leads from the tank well, through the floor, to the gunwale. There is a black residue that makes me think there may be some leakage into the foam where the pipes are molded but could this just be years of mold/ dirt buildup and is this something the factory would have done?

Any help would be appreciated!

[GoneFission]

The 200CCP came with a 73 gallon tank.  Sometimes there was black foam around the entry area into the tank bin.  Check and see if there is a drain hole in the rear of the bin - if not, put one in and put a plug in from the pie plate access in the spashwell.  Otherwise, the bin usually collects water.  You can check it a drain it from time to time if needed with the plug.   Aquasport foamed the sides after the decking was in place, so the hose between the tank bin and the filler tube is hard to remove!  You usually don't have to do that for a tank replacement.  You should replace the other hoses with new USCG approved hose (yes it is expensive!) as part of the tank changeout.  The new tank may come with a new fuel gauge sender or you can just get oneand install it.  Consider a WEMA sender - they last longer and are usually trouble free. 

Phil at Alloy Metal Works has done several tanks for 222 and 200 CCPs and he may have the dimensions to make you a tank.  Their prices are about the best and they usually can do a 1-2 week turnaround.  They did my 22-2CCP tank years ago and I've been very happy with it. 

Good luck! 

[Capt. Bob]

Start here.
https://classicaquasport.com/smf/index.php?topic=11420.msg112280#msg112280

These are the dimensions but unfortunately, the cad drawing is no longer viewable.

Next.
Your third pic shows the original fill and vent hoses from the Factory. As stated, they lead to the vent and fill fittings on the gunnel. You should replace both (hoses) with your new tank install. They are foamed in so removal will be "interesting". It's been done before so I'll look for an old thread or two showing what members did to accomplish this task.

I would suggest you follow the method listed in the link below in the installation of the new tank.
https://classicaquasport.com/smf/index.php?topic=14275.0
You can modify of course but remember that if you use an aluminum tank (one that will match the actual dims that will fit in the coffin) you need to insure that the tank surface stays as dry as possible.

Good luck.

[Capt. Bob]

While this is a different model hull, the method used should give you an idea what you're up against.

https://classicaquasport.com/smf/index.php?topic=6789.msg48839#msg48839

Here is Phil's link. As CJ has stated, he has made many of the replacement tanks used by members on this Forum.

http://alloymetalworks.com/fuel-tanks/4200850

[jdupree]

I just replaced the tank in my '78 200 CCP last year.  It is a 73 gallon.  Sorry it's not a cad drawing, but this is what I sent to Phil at Alloy Metal Works.  The measurements are correct.