I had the same problem as Keith in replacing the fuel filler hose, when I replaced the fuel tank
in my 1988 17 foot Aquasport several years ago. I did not want to cut an additional "access hole"
into the inside hull panel and worked for over an hour attempting to remove the old fuel hose
from inside the hull before concluding that this was an impossible job, without an additional access
hole from which I could attack the old fuel hose.
The reasons why it is so difficult to remove the old fuel filler hose are:
1. the hose clamps at the top end of the hose, usually 2 of them, are very difficult to access.
2. the old hose itself will have hardened over the years so that even though it is rubber it will
be as hard as a rock, not pliable at all.
3. there is little or no space between the outer surface of the hose and the fiberglass of the
boat itself e.g. no "wiggle room", a tight fit. Some forum members have talked about old
hoses that were foamed in place, and the need to break that attachment; my old hose
had no foam anywhere but was a tight fit which was problem enough.
3. that hose from its upper end runs vertically down the side of the boat, but then when it gets
to the floor of the boat turns at a 90 degree angle and runs under the floor to the tank,
under the console. That sharp bend means that you cannot pull the now inflexible hose
from either end and get it out as one piece of hose. You need to cut the hose into
two pieces (as close to the bend as possible) and then remove each piece, thus the need
for a new access hole at that location, so you can cut the hose into two pieces there.
I ended up carefully selecting the site for an additional "access plate" on the starboard inner side
of the hull and cut that acess hole (see below photo). Then I was able to get out the old fuel filler
hose and install a new hose. The attached photo shows an original access plate AND the new
access plate that allowed me to achieve success. It now gives me added access to an
important boat "system". My fuel filler cap is located about 4 inches forward of the
mounting base for my radio antenna, as shown in the photo.
Hope that this will help those who have this chore to perform some day.
You will still need to cut the old hose into 2 pieces to get it out even with these 2 access plates,
due to the sharp bend that the hose takes in going horizontal towards the fuel tank. Any way
you slice it removing the old fuel filler hose is a hard job, but should be done when you replace
your fuel tank.
IMPORTANT DETAIL: --- DON'T FORGET TO TIE A PIECE OF HEAVY DUTY CORD TO THE
UPPER END OF THE FUEL TANK PIECE OF THE OLD HOSE BEFORE YOUR PULL THAT OLD
HOSE OUT. YOU CAN THEN USE THAT CORD TO PULL YOUR NEW HOSE BACK TO THE
"NEW" ACCESS PLATE HOLE. From there you can work the new, pliable hose up the side
of the boat and onto the fuel filler pipe. I connected my new hose first to the upper fuel
filler pipe and only then cut the tank end of the hose to the exact length to best fit onto
the tanks filler pipe.
Coverhill
