Announcement

Collapse
No announcement yet.

Replace or Repair? 1979 Alum Gas Tank

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

    Replace or Repair? 1979 Alum Gas Tank

    Smelled gas at the launch, noticed a very slight trickle in bilge! Went back home and siphoned 94 gallons out. Nasty job. Fuel intake and vent were bone dry -- must have a leak on a weld seam on the bottom. This boat has been garaged its whole life. The tank sure "looks" nice -- inside (see photo) and out, no visible corrosion -- but we can't view the bottom. We'll verify with a pressure test. Gotta pull the engine to get tank out -- then what?

    Is repair advisable on a 1979 aluminum tank? (See photo for specs). If so, any recommendations on a good weld shop between Eugene and Portland OR?

    If replacing is the best option -- aluminum or plastic? Any recommendations on where to get one, tips, etc? Are sizes and shapes fairly standardized?

    Thanks for sharing your experiences-- I get such great direction here!

    Shelly

    Shelly
    Willamette Valley, Oregon
    originally from Seattle

    '80 Saratoga 2550 CB
    Volvo Penta 225D &
    AQ280 outdrive

    - My boat (every photo, ever -- for reference and progress log)
    https://www.flickr.com/gp/[email protected]/esPXUY

    #2
    More than likely you’ll find a section peppered with corrosion. I would replace the tank and upgrade as Bayliner used a thin gauge tank compared to most builders.
    1997 Maxum 2400 SCR 5.7LX Bravo II

    Mike

    Comment


      #3
      Replace the tank. Mine looked a lot like yours on the inside and where you could see the exposed parts. What was under the deck looked like the cratered surface of the moon. One of the tank makers is in Washington. Everett I think. They are not that expensive and shipping to Oregon shouldn't be much. I went with a place out of San Diego. Finding a plastic tank with the size and fittings you need would take luck. Getting one built out of aluminum gets the size you need and the fittings where you need it. -TC


      1977 Saratoga Sunbridge 2550. A project that I hope will be done by the time I retire. See the gory details here- https://www.baylinerownersclub.org/f...ld-gctid659768

      Comment


      • 80Penta225D
        80Penta225D commented
        Editing a comment
        Ours was oi n much better condition (see photos) but I'm replacing it anyway. Thx!

      #4
      The inside looks fantastic because it’s the exterior somewhere at the bottom where you’ll find your leak. As stated previously it’ll likely look like the surface of the moon. Purchase a new tank and know you’ll get another 20 years from it and possibly more if prepared and set in better than OEM.
      Dave
      Edmonds, WA
      "THE FIX"
      '93 2556 5.7 Bravo II 2.0:1 18 1/4x19 P
      (.030 over-Vortec top end-part closed cooled)
      The rebuild of my 2556 https://www.baylinerownersclub.org/f...76?view=thread
      Misc. projects thread
      https://www.baylinerownersclub.org/f...56-gctid789773

      Comment


        #5
        aluminum tanks almost always look new on the inside... with aluminum tanks, they corrode thru from the outside, where as steel tanks usually corrode thru from the inside..

        tanks are expensive to replace and when corroded they are nearly impossible to repair by welding...
        I have had excellent results sealing old tanks using this product https://www.jegs.com/i/Perma-Cool/77...SABEgIEcfD_BwE its an epoxy that adheres well and seals the existing leaks and prevents future leaks. it coats the inside of the tank so it wont corrode from the inside and if the outside continues to corrode, there is a strong membrane to keep the fuel in... for a tank in a damp environment like the bottom of a boat tank, its best to coat the inside, AND paint over the outside where its prone to corrosion.

        nthe only down side is that the tank has to dry for about a week before being filled with fuel... I speed the process up by piping air into the tank from a blower after the treatment, so it drys in about 2 days


        NU LIBERTE'
        Salem, OR

        1989 Bayliner 2556 Convertible
        5.7 OMC Cobra - 15.5x11 prop
        N2K equipped throughout..
        2014 Ram 3500 crew cab, 6.7 Cummins
        2007 M-3705 SLC weekend warrior, 5th wheel
        '04 Polaris Sportsman 700 -- '05 Polaris Sportsman 500 HO
        Heavy Equipment Repair and Specialty Welding

        Comment


          #6
          My recommendation is to coat the outside of your new aluminum tank with epoxy, picture of my tank coated.
          Slightly modified 2859 6.5 Diesel Bravo III X drive
          96 Dodge 5.9 5 speed Gear vender OD.

          Comment


          • 80Penta225D
            80Penta225D commented
            Editing a comment
            Fritzman, what kind of epoxy did you use to coat your tank?

          #7
          The problem with aluminum fuel tanks is: The factory should have had poly strips under the tank with a full coverage of sealant between the tank and the base.
          I believe new boats are not allowed to have aluminum fuel tanks now.
          Most of the corrosion will be under the tank, I have replaced a few, same with aluminum water tanks.

          I believe I am wrong on the aluminum tank issue!
          Aluminum tanks cannot be encased in foam.
          Last edited by boatworkfl; 04-20-2019, 11:32 AM.
          Pat says: DO-IT-RIGHT THE FIRST TIME!

          Bayliner 3870 "ALASKA33)
          Twin 350 GM power
          Located in Seward, AK
          Retired marine surveyor

          Comment


            #8
            Wow -- great feedback and advice!

            The majority says "Replace" but I clearly have options. Thanks for the link, CL. Gotta get the tank out and properly assess the situation first. I'm pretty sure the purchase of a new tank is in my near future, tho. Especially after seeing TommyTs pictures. We'll make sure the "bed" is prepared above OEM standards, and coat the tank before installing.

            Stay tuned for pictures after tank comes out.

            THANKS for the input. Very, very helpful. Additional comments are welcome.

            Shelly

            Last edited by 80Penta225D; 01-13-2019, 12:21 PM. Reason: Hit 'Post' by accident
            Shelly
            Willamette Valley, Oregon
            originally from Seattle

            '80 Saratoga 2550 CB
            Volvo Penta 225D &
            AQ280 outdrive

            - My boat (every photo, ever -- for reference and progress log)
            https://www.flickr.com/gp/[email protected]/esPXUY

            Comment


              #9
              Originally posted by 80Penta225D View Post
              Wow -- great feedback and advice!

              The majority says "Replace" but I clearly have options. Thanks for the link, CL. Gotta get the tank out and properly assess the situation first. I'm pretty sure the purchase of a new tank is in my near future, tho. Especially after seeing TommyTs pictures. We'll make sure the "bed" is prepared above OEM standards, and coat the tank before installing.

              Stay tuned for pictures after tank comes out.

              THANKS for the input. Very, very helpful. Additional comments are welcome.

              Shelly
              Use plenty of 4200 on the 1/4"/1/2" poly strips under the tank whether using metal or poly tanks, no wood!
              Pat says: DO-IT-RIGHT THE FIRST TIME!

              Bayliner 3870 "ALASKA33)
              Twin 350 GM power
              Located in Seward, AK
              Retired marine surveyor

              Comment


                #10
                Originally posted by boatworkfl View Post

                Use plenty of 4200 on the 1/4"/1/2" poly strips under the tank whether using metal or poly tanks, no wood!
                Ok, will do -- thanks!

                The manufacturer's tag says the aluminum is .125" thick. It lasted 39 years, so I guess I can't complain.

                The engine and tank will be pulled out 3 weeks from now . Photos to come.

                Shelly
                Shelly
                Willamette Valley, Oregon
                originally from Seattle

                '80 Saratoga 2550 CB
                Volvo Penta 225D &
                AQ280 outdrive

                - My boat (every photo, ever -- for reference and progress log)
                https://www.flickr.com/gp/[email protected]/esPXUY

                Comment


                  #11
                  Good time to inspect and or upgrade things in the engine bay while it’s empty.
                  Good luck with the project
                  Dave
                  Edmonds, WA
                  "THE FIX"
                  '93 2556 5.7 Bravo II 2.0:1 18 1/4x19 P
                  (.030 over-Vortec top end-part closed cooled)
                  The rebuild of my 2556 https://www.baylinerownersclub.org/f...76?view=thread
                  Misc. projects thread
                  https://www.baylinerownersclub.org/f...56-gctid789773

                  Comment


                    #12
                    "New boats are not allowed to have aluminum fuel tanks now."
                    Says who? I haven't heard that before...

                    https://www.boats.com/how-to/fuel-tank-awareness-2551/
                    Joon, Kathy, Jaden & Tristan
                    Uniflite 42 AC, DD 671N
                    93 3058 sold
                    92 2855 (day boat)
                    91 Fourwinns 205 (lake boat)
                    Longbranch WA
                    Life is Good

                    Comment


                    • 80Penta225D
                      80Penta225D commented
                      Editing a comment
                      Great article on gas tanks -- thanks!
                      Shelly

                    #13
                    I read it somewhere but I cannot find it, it may be just for new boats.
                    I believe I am wrong on the aluminum tank issue!
                    Aluminum tanks cannot be encased in foam.
                    Last edited by boatworkfl; 04-20-2019, 11:33 AM.
                    Pat says: DO-IT-RIGHT THE FIRST TIME!

                    Bayliner 3870 "ALASKA33)
                    Twin 350 GM power
                    Located in Seward, AK
                    Retired marine surveyor

                    Comment


                      #14
                      It might be that the OEM is lucking at cost for Poly compared to Aluminum?
                      Slightly modified 2859 6.5 Diesel Bravo III X drive
                      96 Dodge 5.9 5 speed Gear vender OD.

                      Comment


                        #15
                        The gas tank replacement project got sidelined due to some work required on a rental house. Just finishing that up. So....

                        My brother is coming down next Friday to help pull the engine (it's ready to hoist) and tank. He replaced the tank on his '77 Nisqually 23' as part of a total restore. We'll install the diesel air heater, too (see my other post on that).

                        Pictures coming after next weekend.
                        Stay tuned!

                        Shelly
                        Shelly
                        Willamette Valley, Oregon
                        originally from Seattle

                        '80 Saratoga 2550 CB
                        Volvo Penta 225D &
                        AQ280 outdrive

                        - My boat (every photo, ever -- for reference and progress log)
                        https://www.flickr.com/gp/[email protected]/esPXUY

                        Comment

                        Working...
                        X