It was probably too much to ask for an aluminum fuel tank to last 30+ years.
Pin holes develop in tanks over time. I had one pin hole leak welded a decade ago and had a new one beginning. It was not going to fix itself, and to respect the environment and avoid any unnecessary discharge I decided that while it could be fixed, it was going to be a losing battle. I stretched the life of the old tank about as far as it could go ... so out it came.
The new tank, the boats third (above) replaced the off-the-shelf unit that held gasoline prior to 2001 back when the boat was powered by an old Palmer engine. So this was the second tank that had failed in 46 years, not too bad.
Since I basically replaced the entire fuel delivery system last year; new fuel lift pump, all the gaskets and hoses, etc., it seemed prudent to complete the task with a new tank. New is good!
I wanted someone local to do the work as there was a bit of discussion and on the custom modifications. I also wanted to make sure the tank fit better in it's cradle. This entailed pulling the old tank, taking it in to discuss the options, then creating a cardboard mockup to ensure the new tank would fit.
I had Hatton Marine Fabrication build a custom tank to United States Coast Guard and Environmental Protection Agency - Compliance Guidelines and my requirements for shape and volume. It was made from 3/16" 5052 aluminum alloy and holds roughly 26-27 gallons (182-188lbs). The exterior dimensions are 10"h x 26"l x 22"w. The port side is cut at an angle to add a bit more capacity.
There was no USCG certification stamp or sticker supplied by Hatton, but the Coast Guard inspector says "tank certifications are not necessary unless the tank is going in a COI (certificate of inspection) vessel, like subchapter T passenger ferry."
I also added an 8 1/4" x 8 1/4" inspection plate to assist in the bi-annual clean out. And while the tank was out I took the opportunity to clean up the wiring by adding wire wraps and suspending the wiring well above the tank.
Nothing is ever 100% done, and I am currently consulting with a surveyor and working out the details on the last few things:
- Vented loop on vent line
- Strapping
- Return line bend too tight
- Slightly uneven base
Luckily the port lazaretto is huge with lots of access!
The old tank was good for almost 30 years!
