Welcome, Guest
Username: Password: Remember me

TOPIC: Replacing Fuel Tank 2855

Replacing Fuel Tank 2855 14 Aug 2011 15:26 #1

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
Well, after much research, study & encouragement from you guys I decided to take this project on myself. I was getting ready to drop the boat off at the marina to have the engine replaced when I discovered the gas leak. The new (re-manufactured) engine was covered under warranty & so was not going to cost us anything. The new fuel tank on the other hand was all on us. I received 3 estimates ranging from $5500 to $4500. I know a new aluminum 110 gal. fuel tank is around $1000 (inc, tax & frt,) of that & the rest is mostly labor @ $90 per hour. Ouch!!! I can't see putting any more money into this "Hole in the water that all of our money seems to go" than we have to.

This image is hidden for guests.
Please log in or register to see it.


I had the marina go ahead & take the engine out since that was going to happen anyway. This way I will have more room to work. I think I will need all that I can get.

This image is hidden for guests.
Please log in or register to see it.


Here is the view to the aft cabin from inside the boat. I don't think that I will be taking the tank out this way if I can help it. If the engine were still in the boat I would obviously not have a choice.

This image is hidden for guests.
Please log in or register to see it.


After removing the upper panel in the aft cabin I discovered a big unsealed hole that accessed the engine compartment. For some reason I was under the impression that the cabin was isolated & sealed from the fumes that would come from the engine compartment. I guess I was wrong.

This image is hidden for guests.
Please log in or register to see it.


Here is another hole on the other side. I guess this one lets the fumes out. This must explain my wife's long naps in the aft cabin on the way back from our cruises.

This image is hidden for guests.
Please log in or register to see it.


It looks like there are only four bolts holding the back wall of the aft cabin to the upper deck. Nothing is sealed "air tight". I have to say that I am less then impressed with this construction.

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 14 Aug 2011 16:41 #2

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
The game plan is to cut out the floor in the aft cabin half way over the stringers (which are two inches wide) so that when I go to replace the floor I will have a ledge to set the floor back on. I am also going to go all of the way up the back aft cabin wall. I will add temporary supports to the upper deck if it looks like I will need it. I will know when I remove the two bolts that are holding the piece that I am planning to cut. I will still have the back wall support on both sides so I don't think that it will be an issue. The blue tape is the exact (I hope ) stringer location.

This image is hidden for guests.
Please log in or register to see it.


I want to try and get the floor & wall out in one piece so that the re-install will be easier, if not I will cut where I have to.

This image is hidden for guests.
Please log in or register to see it.


I guess I need to remove all of this crap from the back wall before I take a saw to it.

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 14 Aug 2011 17:16 #3

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
As a safety precaution I am going to flush the fuel tank with water. The hole in the tank must be at the very bottom because there is almost nothing left in the tank, at least not enough that I am able to capture with a pump.

This image is hidden for guests.
Please log in or register to see it.


Here is the water coming out of the fuel sending unit hole. This way I know it is rinsing the inside top of the tank also. I am going to be super careful while cutting, but I also want to do everything possible to be safe.

This image is hidden for guests.
Please log in or register to see it.

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 14 Aug 2011 23:31 #4

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
I decided to put some boards down as guides for the circular saw. I will start off at 1/2 inch & work my way deeper as needed.

This image is hidden for guests.
Please log in or register to see it.


The two side cuts are made. I see day light. In this case it is a good thing.

This image is hidden for guests.
Please log in or register to see it.

Now I cut the front edge & was able to break it free & move the whole piece forward with the help of crow bars, screw drivers, hammers, cussing, prying and praying.

This image is hidden for guests.
Please log in or register to see it.

I did have to finally cut it in two pieces to get it out of the aft cabin. OK, honestly it broke in two pieces taking it out. Oh well!

This image is hidden for guests.
Please log in or register to see it.

That's enough for today. Tomorrow I will cut away the fiber glass & pop that sucker out of there.

This image is hidden for guests.
Please log in or register to see it.

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 15 Aug 2011 03:07 #5

  • Four Pyrates
  • Four Pyrates's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
  • Posts: 2475
  • Thank you received: 145
With the engine out it should be some quick work. Nice job.

Please Log in or Create an account to join the conversation.

Replacing Fuel Tank 2855 15 Aug 2011 03:22 #6

  • biohazard
  • biohazard's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
  • Posts: 4705
  • Thank you received: 1
great work tony, shes coming along nicely.

Please Log in or Create an account to join the conversation.

Ryan
Hastings, Minnesota

This image is hidden for guests.
Please log in or register to see it.


"Sonnie Due"
1999 Bayliner Ciera 3055
Twin Mercruiser 5.7L Bravo 2[/FONT]
MMSI : 338122217
"If you wish to make an apple pie from scratch, you must first.....invent the universe"
- Carl Sagan

Replacing Fuel Tank 2855 15 Aug 2011 04:02 #7

  • Old Bull
  • Old Bull's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 62
  • Thank you received: 2
Heck yes! I bet your holes are right in the bottom aft part on the tank where water pools. I have mine out now but before she goes back in she'll be blocked-up with 1/4" starboard for ventilation. looking real good!

Please Log in or Create an account to join the conversation.

1989 2958 Command Bridge
"No Name yet"
Charleston, SC

Replacing Fuel Tank 2855 15 Aug 2011 14:52 #8

  • dewman
  • dewman's Avatar
  • Offline
  • Elite Member
  • Elite Member
  • Posts: 575
  • Thank you received: 13
Well you're committed now :) Looks like you are doing good work. I thought about taking my tank out the same way you are doing it and doing some proactive maintance, but I just had too many things on my plate at the time. It will be nice when you are all done, and you will have some tremendous peace of mind. Keep those pictures coming!

Please Log in or Create an account to join the conversation.

1980 Saratoga 2550 SOLD
1999 Regal 2760
MMSI 338121957

Replacing Fuel Tank 2855 15 Aug 2011 15:41 #9

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
Even with all of the fiberglass removed the tank is not budging.

This image is hidden for guests.
Please log in or register to see it.


This is one of two wedges that are glassed in apparently to hold the tank in place. The other one is at the opposite corner at the other end.

This image is hidden for guests.
Please log in or register to see it.


This bulkhead is rotten in several areas. I may as well remove & replace it while I am at it. This way I can get under the tank & carefully pry it out. I sure hope that they didn't glue it in!!!

This image is hidden for guests.
Please log in or register to see it.


This image is hidden for guests.
Please log in or register to see it.


Even with the wedges cut away the tank is not budging. Time to cut out this bulkhead!!!

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 15 Aug 2011 15:47 #10

  • biohazard
  • biohazard's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
  • Posts: 4705
  • Thank you received: 1
I wonder if you shoved a bar in the sending unit hole with a chain on it, if you could winch it out like that. Just run the chian in the middle of the bar and have the ends long enough so they cant slip back out. I would hope they didnt glue it in place.

Please Log in or Create an account to join the conversation.

Ryan
Hastings, Minnesota

This image is hidden for guests.
Please log in or register to see it.


"Sonnie Due"
1999 Bayliner Ciera 3055
Twin Mercruiser 5.7L Bravo 2[/FONT]
MMSI : 338122217
"If you wish to make an apple pie from scratch, you must first.....invent the universe"
- Carl Sagan

Replacing Fuel Tank 2855 15 Aug 2011 15:52 #11

  • Old Bull
  • Old Bull's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 62
  • Thank you received: 2
Mine was in there real good too.
To good in my opinion.
I consider a fuel tank a wearable item that should be installed for future maintenance during the construction.
Gotta love Bayliner's boat building practices.

I see your in Florida, are you felling a little claustrophobic in that hole with all the heat?

You are doing a great job with the photo documentation. This would have been a big help for me a couple of weeks ago. keep them coming........

Please Log in or Create an account to join the conversation.

1989 2958 Command Bridge
"No Name yet"
Charleston, SC

Replacing Fuel Tank 2855 15 Aug 2011 17:48 #12

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1

Old Bull;603278 wrote: Mine was in there real good too.
To good in my opinion.
I consider a fuel tank a wearable item that should be installed for future maintenance during the construction.
Gotta love Bayliner's boat building practices.

I see your in Florida, are you felling a little claustrophobic in that hole with all the heat?
You are doing a great job with the photo documentation. This would have been a big help for me a couple of weeks ago. keep them coming........


Yes, I guess you could say it's hot.

This image is hidden for guests.
Please log in or register to see it.


Of course that is in the shade and it did go up to 108 after I took that picture!

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 15 Aug 2011 20:46 #13

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
Holy crap that was a lot harder than it looks!!!

This image is hidden for guests.
Please log in or register to see it.


That was harder than taking out the other stuff due to the angle of the cuts, the toughness of the fiberglass & the fact that it was right up against the tank. I still want to see what what is causing the leak so I don't want to damage it just in case it is a simple repair. The tank STILL won't budge, but to be honest with you my hands feel heavy right about now so maybe it is just me. The starboard side of the tank is totally not touching anything. I am able to run a hand saw all along the side with no binding. I will try & carefully pry that side up first tomorrow morning after I recoop.:surr Where is the 800 mg Ibuprofin & the Miller Lite honey???!!!

Also, I want to thank Ed (Astral Blue) for suggesting this tool. I don't know how I would have taken out that bulk head without it. Plus now I have another cool tool!! :cool
http://www.harborfreight.com/power-tools/oscillating-tools/oscillating-multifunction-power-tool-68303.html.
I actually bought the cordless version of this. It was also on sale, but I should have bought an extra battery. :oops

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 16 Aug 2011 20:29 #14

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
That tank was in there tight. I went to Home Depot & bought $75 worth of chain, a hoist, a bunch of different size hardware to somehow attach to the tank & break it free. I was also using a 10' long 2" in diameter pipe that I already had. The pipe was setting on the gunnels over the engine compartment on top of some wood to protect the gelcoat & disperse the weight. Long story short, the hoist broke free of the tank, the pipe (which probably weighs over 50lbs) bounced over my head while I was standing in the engine compartment. Luckily the pipe missed my head & also didn’t drop into the engine compartment. I unhooked everything & said thanks to the “Good Lord” for sparing such an idiot from harm. I ended up using an old rusty crow bar that I had laying around & a scrap piece of wood to pry one end of the tank up. After that, it just came right out & was much lighter that I expected. My wife came out just as it was standing upright in the engine compartment. She offered to call someone to help me, God bless her, but I said by the time they get here I will have this thing sitting in the yard.

This image is hidden for guests.
Please log in or register to see it.


This image is hidden for guests.
Please log in or register to see it.


I feel like the guys at the dock when they bring in a shark & string him up for everyone to see!!!

This image is hidden for guests.
Please log in or register to see it.


This is where the leak was coming from. There are several other spots of major corrosion where is is almost through. They are ALL where the RUBBER straps were touching the tank. Thank you Bayliner. I have since learned that rubber is a NO NO.

This image is hidden for guests.
Please log in or register to see it.


This image is hidden for guests.
Please log in or register to see it.

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 16 Aug 2011 21:40 #15

  • douglee25
  • douglee25's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 40
  • Thank you received: 0
So will you be fixing it or getting a new one?

Doug

Please Log in or Create an account to join the conversation.

Replacing Fuel Tank 2855 16 Aug 2011 22:54 #16

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
We are getting a new one. My wife won't sleep on top of a repaired 110 gal. fuel tank, go figure.:D

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 17 Aug 2011 01:34 #17

  • douglee25
  • douglee25's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 40
  • Thank you received: 0
I don't blame her!

Doug

Please Log in or Create an account to join the conversation.

Replacing Fuel Tank 2855 17 Aug 2011 01:47 #18

  • gijoe081968
  • gijoe081968's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 41
  • Thank you received: 0
Not sure if you have a line on a new tank yet but if not you might want to try RDS in Perry, FL. I ordered a 105 gal tank from them and it was spot on. Good price, and fast turn-around.
Love the thread and great job so far.

Please Log in or Create an account to join the conversation.

1989 Ciera 2556 Command Bridge
5.7L

Replacing Fuel Tank 2855 17 Aug 2011 03:18 #19

  • Old Bull
  • Old Bull's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 62
  • Thank you received: 2
Way to kick that tanks A$$!!

Please Log in or Create an account to join the conversation.

1989 2958 Command Bridge
"No Name yet"
Charleston, SC

Replacing Fuel Tank 2855 17 Aug 2011 03:32 #20

  • biohazard
  • biohazard's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
  • Posts: 4705
  • Thank you received: 1
Nice work man what a pita!:cool

Please Log in or Create an account to join the conversation.

Ryan
Hastings, Minnesota

This image is hidden for guests.
Please log in or register to see it.


"Sonnie Due"
1999 Bayliner Ciera 3055
Twin Mercruiser 5.7L Bravo 2[/FONT]
MMSI : 338122217
"If you wish to make an apple pie from scratch, you must first.....invent the universe"
- Carl Sagan

Replacing Fuel Tank 2855 17 Aug 2011 14:58 #21

  • Guest
  • Guest's Avatar
  • Visitor
  • Visitor
Awesome job Tony. That's a prime example of 'Yankee Ingenuity'.

Are you thinking plastic or aloobinum for the new tank?

Please Log in or Create an account to join the conversation.

Replacing Fuel Tank 2855 17 Aug 2011 14:59 #22

  • dewman
  • dewman's Avatar
  • Offline
  • Elite Member
  • Elite Member
  • Posts: 575
  • Thank you received: 13
Love the conquering hero pose!

Please Log in or Create an account to join the conversation.

1980 Saratoga 2550 SOLD
1999 Regal 2760
MMSI 338121957

Replacing Fuel Tank 2855 17 Aug 2011 20:56 #23

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1

freedre;604068 wrote: Awesome job Tony. That's a prime example of 'Yankee Ingenuity'.

Are you thinking plastic or aloobinum for the new tank?


I wanted titanium but its not in the budget. We are going with aluminum from the same company (RDS, thank you gijoe) that made the original. This way everything "should" line up & fit correctly. :D

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer

Replacing Fuel Tank 2855 18 Aug 2011 03:42 #24

  • jimmcgee5
  • jimmcgee5's Avatar
  • Offline
  • New Member
  • New Member
  • Posts: 49
  • Thank you received: 0

dewman;604069 wrote: Love the conquering hero pose!


:D i'm thinking 12g and a backroad out off town lol:arr

Please Log in or Create an account to join the conversation.

2255 sunbridge
3.0 , top speed unknown, 3 speedos and none working:p

Replacing Fuel Tank 2855 19 Aug 2011 19:24 #25

  • Tony B
  • Tony B's Avatar Topic Author
  • Offline
  • Premium Member
  • Premium Member
  • Posts: 331
  • Thank you received: 1
Here is where the gas tank used to be. With fuel prices they way they are, we were considering just leaving the tank & engine out & making a nice large stateroom out of the two areas. I could hook up a little 9.9hp 4 stroke so that we can still tool around the lake. Sounds like a plan to me.

This image is hidden for guests.
Please log in or register to see it.


This image is hidden for guests.
Please log in or register to see it.


That sure is nasty. I am going break out the "Purple Power" degreaser & go to town. I am also going to make sure those drain holes are wide open. I have to make sure this area stays dry after the tank is installed. :D

Please Log in or Create an account to join the conversation.

Tony :D
1998, Bayliner 2855 Ciera
Mercruiser 502 (415hp)
Bravo III
2006, Aluminum (bunk) trailer
Moderators: whiskywizarditsabowtime2
Time to create page: 0.163 seconds
Powered by Kunena Forum