Fuel Tank Replacement 87 V20
 

I am going to try to get this started and attach pictures.
First pic is of open hatch and console moved to allow access to tank area.Attachment 948

next pic is of the console moved showing tank area
Attachment 949

Next the hoses, wires etc removed and ready to begin removing foam..
Attachment 950

The tank is out..
Attachment 951

See the holes, there were more under the bottom area..
Attachment 952

Tank replacement cont..
 

next picture is the tank showing the overall condition after 22 years encased in foam..Attachment 953

this is the coffin area after the tank has been removed, notice the PVC pipe running from bulkhead to bulkhead through the foam. This drained the foreward compartment areas to the rear bilge where the bilge pump is.
Attachment 954

This is the rear of the coffin bulkhead showing how the PVC is run.
Attachment 955

The dark area is where I had spilled some outboard oil and it stained the bulkhead, it's still solid all the way around as seen in the next two pics...
Attachment 956
Attachment 957

Tank replacement cont..
 

OK first pic is the front of the coffin bulkhead showing the condition of the interior and bilge area, still good for 22 years I think..
Attachment 958

Next the coffin area is cleaned out and ready for prep.
Attachment 959

New tank, prepped with coal tar epoxy, ready to be put into coffin..
Attachment 960

I prepared the coffin area with foamed in bulkheads to allow for water drainage from sides and front to rear and to allow air circulation around tank
Attachment 961

I used a template to cut and shape the foam bulkheads to fit the tank and support it while I poured foam into the four corners..
Attachment 962

Tank replacement cont..
 

After I cut the foam bulkheads to fit, I epoxied the entire compartment and foam bulkheads to seal everything before I dropped in the new tank.

The nex pic is the new tank in place with hold downs in place to keep the tank from rising when I poured the foam in..
Attachment 963

This is the coal tar epoxy I used to coat the tank with, it only cost $23
Attachment 964

After changing all of the hoses and filters and everything associated with the fuel system, I am very confident of the condition of my boat now. I also had stuck the camera into all of the holes and inspection ports to be able to check unreachable areas. Worked out great..
I can't figure out how to insert big pictures yet. This is still a learning experience for me....
Thanks for all of the help guys..

Tommy

Man, that looks good!!
D'yu run a bonding strap for lightning and/or static electricity protection between the nozzle filler, tank and zinc plate or motor ground?

man, that coal tar is tough stuff, where did you find it so cheap?

There were two grounding tabs built on the topside of the tank, grounding wires were run from filler to tank, vent to tank, tank to battery ground, tank to ground block on panel. Is this the same as a bonding strap like you mentioned? ( I hope so, I would hate to find out now I need to go back into the project) I failed to mention how long it took! Started in January 2009, finished around end of March 09, working weekends between all of the other honeydos...
Learned a lot from the internet forums.... I would not have tried it without all of the help. I think I might haved saved a few dollars doing it my self..

The brand is BP and there is a BP paint store here in my area. I had checked with another paint store and a similar product was around $54, believe it or not the salesman at the paint store told me about the BP store. I had printed out the pic to use for shopping......

Great info there Rabbitfish, thanks for posting....I have my tank replacement on the horizon, this fall/winter. Not sure if I have the patience to do as good a job as you though....

looks good, did you put cloth over the new foam supports, or just coat with epoxy? i have a feeling i am due for the same type project in the future....