Fuel tank Replacement on '86 Aquasport Osprey 200

[CThomps]

So this is the next project for the aquasport.  As far as I know the boat still has the original fuel tank.  I've been running a 20gallon portable for months now.  I'll be doing the removal on a boat lift.  The lift itself could come in handy for lifting the tank out of the well.  

Does anyone have any pictures of a tank being replaced?  

I guess speedytanks is probably the way to go as far as getting a new tank.  Unless I can find an off the shelf tank that will fit.  Even if the tank is slightly smaller than the original.  40gallons is probably all I need.

[MarshMarlowe196]

The lift should come in handy for pulling that tank out.  I don't have any pictures of pulling my tank out, but it wasn't too complex.  Pull the tank lid off, dig all that foam out from around the tank (PITA), unfasten the straps going across the tank,  disconnect the hoses/grounding wire(s), use something like a crowbar to pry the tank up slightly, get a lifting strap and work it under the tank, attach the strap to your lift and pull that thing out.  

I didn't replace my tank because, somehow, it was in good condition when I pulled it out.  I'm sure someone will chime in on where to get a good tank made/ordered; that seems to be a pretty active topic on this site.

[GoneFission]

Here's the step by step for replacement of the tank on my 22-2CCP:

http://classicaquasport.com/smf/index.php?topic=2597.0

See ya on the water!!

[CThomps]

Here's the step by step for replacement of the tank on my 22-2CCP:

http://classicaquasport.com/smf/index.php?topic=2597.0
See ya on the water!!

Did you reglass that whole cracked area?  Just wondering what I should have on hand in case I come across cracks like those.

[GoneFission]

I reinforced it from the bottom, and put a layer of cloth on the top.  I felt I could get a better bond on the unfinished glass on the bottom side, and also don't need to worry much about how it looks...  

[CThomps]

Good stuff.    :)

[CThomps]

What did you use for cushioning ing under the tank?

What kind of foam did you use?  I noticed that the foam was kind of strategically placed.

[Kevin]

I am going thru this process right now. my boat is an 1988 20 ft osprey . after taking off console and floor , the tank was secured only with Stainless steel Banding straps, no foam. there is just a rubber or neoprene material between tank and stainless strap. The Aluminum doesn't want to touch the stainless. There was nothing else in that enclosed tank well area.    The original tag was still on it and I found the company in Perry fl. It is RDS aluminum . They had the plans for my tank  the lady I'm dealing with is  linda Wiles     lwiles@rdsaluminum.com. The plans exactly match my tank. I haven't ordered it yet,      
The issue I have now is resecuring the new tank. I haven't called my yard that I am buying engine from , Hopefully he has a banding machine. The label on the band was Denver Banding Co and is about 1 inch wide.

Good luck
 Kevin

[CThomps]

Thanks Kevin.  I wonder if my tank was made by the same company.  I guess I'll find out in a few weeks when I pull it out.  

Perry is about a 5 hour drive for me.  That's doable.

[CThomps]

So out came the fuel tank on Saturday.  

This wasn't nearly the hellish job I was anticipating.  It took us 3 hour start to clean up to get the tank removed.  And we were taking our time doing it so as not screw anything up.  I figure securing the new tank once we get it will take about 2-3 hours being that we know what we're doing.

So for anyone who's unsure if they want to try this I say go for it.  We didn't even have to disconnect anything from the center consul.  It was easy as undoing the the screws from the consul and the flip back seat, leaning it to starboard, taking out all the screws from the coffin lid, taking it off, clipping the stainless straps, disconnecting the fuel lines and sender lines, and popping out the tank.  There was no foam holding it in place.  I wouldn't have even called it a hard job.  

We've been running a portable 20gal tank for weeks now so we put everything back together so we could run the boat while waiting on the tank.  

It was electrolysis that killed the tank.  The stainless straps had rubbed through the crappy foam that was in between the tank and thr straps.  And at some point in history the sender had been replaced but the gasket had not.  One thing led to another and there were little half pea hole spot were you could see where the straps had made contact with the tank.  

Now to order the tank.

[CThomps]

RDS aluminum quoted me $526 for my new tank for the '86 20ft Osprey.

Damn thing is a 60 gallon tank.  I always thought it was smaller.

I may have 2 3/4 inches shaved off the length of the tank.  That could make it slightly less expensive.  

Sheets of aluminum come in 12ft lengths.  So half a sheet could build the entire tanks from what I can tell.  

I got a quote from a local welder and he wanted $685.  But his are custom welding jobs.  He had heard of RDS and had nothing bad to say about them.