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Capri 1800 LS - Gas tank leak! Advice needed-gctid358338

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    Capri 1800 LS - Gas tank leak! Advice needed-gctid358338

    Hello all!

    I'm new to this forum and boating in general so please bare with me as I may not know all the correct terminology.

    I have a 1995 Bayliner Capri 1800 LS with a 120 Force O/B motor that I bought last summer. The boat ran good but needed some minor tweaks with the motor as it was rough idling and had difficulty starting up sometimes. I resolved those problems over the winter and the boat fires up great.

    I noticed some liquid in my ski locker that appeared to be gas/oil mix, smelled just like it too. I first noticed this at the end of last season. I took the boat to my sister's house to be stored and my BIL asked what the heck that smell was. We tried spraying it out with a hose and eventually got it all out -OR- so we thought. I had a marine mechanic due some repairs and pressure test the tank. The boat probably had about 6 gallons of gas/oil mix in there when he did the repairs. I got the boat back with a clean bill of health. Motor fired right up and he said the gas tank pressure tested out fine.

    When I went back to get my boat in Feb., I noticed that smell again and confirmed there was liquid in the ski locker again!! We stuck a wire from the drainage hole from the ski locker back to the bilge pump area to ensure there wasn't any leaves obstructing the flow. Sprayed out the liquid again which took a long time to drain out of the ski locker and slowly into the bilge pump area and finally out the drainage hole of the boat.

    I tried starting the boat with the hose and muffs on but the tank was bone dry - No gas getting to the motor from the bulb that was just replaced. Finally made it back home and looked in the storage locker and there was still a little bit of liquid in there. Makes me question the results of the pressure test or maybe there was a hair line fracture that went undetected.

    I filled another 12 gallons of gas/oil mixture and headed to the lake. While out there, I noticed that there was alot of liquid in the ski locker. I've checked the gas fill hole and the other hoses around the tank and everything seems to be dry and no signs of dry rot. I think there's something larger going on below the deck. Problem is, the gas tank is embedded below the deck and I have no access unless I rip up the deck.

    Before leaving the lake I dumped about 10-15 gallons of lake was in the ski locker and let it drain from the incline of the ramp. Seems like it all drained out but checked again when I parked the boat and the some liquid is still present in the ski locker. I've never had this problem before and in fact, there's hardly ever any water when I pull the drain plug after a long day on the lake.

    The odd thing is, there will be liquid in the ski locker and none present in the bilge pump/transom area. I don't know if it's a design flaw but I would think the very rear of the boat should be the lowest point for gravity to work it's course and drain any liquids. I had to raise the tongue of the trailer as high as it would go for liquid to finally make it's way out the boat.

    I think I'm going to have to cut up the deck and probably replace the tank.

    Does anyone have any recommendations on how to do this, the tools needed, where to purchase a new tank and of what material. I think the one in there is aluminum. I've read on a different thread that you can coat the tank with some material to prolong the life. How much can this cost to repair?

    I'm reluctant to cut up the deck without some advice because of the potential explosion waiting to happen if I create a spark.

    I'm at a loss here folks and would appreciate all the help/advice. I usually hit the lake at least once a week and would hate to miss the whole season.

    Sorry for the long winded overview, I figure more is better. Thanks in advance!

    #2
    Try and find the acess hole for the fuel level float, it may be the gasket , or it may be the hose connection, do this first.

    The 2 bilge compartments may not be connected for the reason of a leaky tank draining fuel into the engine room.
    Pat says: DO-IT-RIGHT THE FIRST TIME!

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

    Comment


      #3
      Hi 95Bayliner,

      Sounds like we are going through the exact same situation. The thing is these gas tanks are aluminum and only last maybe 10 years.

      I have a 1998 Trophy 2002 W/A ~ My tank is a coastline model 823-B. I just recently ordered a new tank to be built by the original manufacturers (http://coastline-tanks.com/bellytanks.html) because ours is leaking gas.... I just delivered the boat to the shop installing it today. They are going to email pics to me once they cut the deck open. I'll try and post them so you can see.

      We paid $800 total to have the new gas tank made (aluminum) and shipped from Washington state to California. We are paying $4,000 to the shop to cut out the deck, install the new tank, replace all fuel lines, check the bildge for anything else before they close it back up! I am having them double clamp and glue the bait well as I understand they leak like a sieve and I'm going to use it to store my washdown hose in!

      We are new to boating too. The guy we bought the boat from said he "spilled gas from his portable gas tank in the cuddy" ~ we learned the hard way. Too bad there are A******S out there like that. Its okay, the boat is in great shape otherwise.

      Good luck to you!

      C legs

      Comment


        #4
        Since you have an OB you may want to abandon the belly tank for now and run this season with regular OB portable tanks.

        That buys you time while you decide if it's cost effective to rip out the old tank.

        Comment


          #5
          Hello Mariner,

          We considered that as a possible permanent option, but it would take up too much deck space and we would be filling them constantly as our current

          tank holds 82 gallons and we would have maybe two 8 gallon portables ~ something like that....but you are right...its a quick fix until you decide what to do. We just went ahead and bit the bullet and are taking care of it....

          C Legs

          Comment


            #6
            First check for that access hole for the fuel guage and inspect as much as you can from there.
            Pat says: DO-IT-RIGHT THE FIRST TIME!

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

            Comment


              #8
              The shop working on it isn't open yet so I haven't been able to ask them about these pictures ~ I can see the gas tank corrosion, but I'm wondering about the condition of the hull now........what do you think?

              C legs

              Comment


                #9
                The hull has to be inspected for delamination by hand. I don't see anything obvious but that isn't good enough. What I do see is that water in the bilge caused the steel tank straps to corrode the aluminum tank. A warning for the rest of us.

                Good Luck, hold on to your wallet!

                Comment


                  #10
                  The shop said that they used RUBBER straps which trapped moisture against the tank and everywhere it touched it was corroded. They are using some kind of mesh strapping that will breathe. He said the stringers look good. They are going to clean it all out and will be looking at the bait well today.....stay tuned! I expect more pics to come in.

                  C legs

                  1998 Trophy 2002 WA

                  Comment


                    #11
                    clegs wrote:
                    Hi 95Bayliner,

                    Sounds like we are going through the exact same situation. The thing is these gas tanks are aluminum and only last maybe 10 years.

                    I have a 1998 Trophy 2002 W/A ~ My tank is a coastline model 823-B. I just recently ordered a new tank to be built by the original manufacturers (http://coastline-tanks.com/bellytanks.html) because ours is leaking gas.... I just delivered the boat to the shop installing it today. They are going to email pics to me once they cut the deck open. I'll try and post them so you can see.

                    We paid $800 total to have the new gas tank made (aluminum) and shipped from Washington state to California. We are paying $4,000 to the shop to cut out the deck, install the new tank, replace all fuel lines, check the bildge for anything else before they close it back up! I am having them double clamp and glue the bait well as I understand they leak like a sieve and I'm going to use it to store my washdown hose in!

                    We are new to boating too. The guy we bought the boat from said he "spilled gas from his portable gas tank in the cuddy" ~ we learned the hard way. Too bad there are A******S out there like that. Its okay, the boat is in great shape otherwise.

                    Good luck to you!

                    C legs
                    Hey C Legs,

                    Sorry to hear that you're experiencing the same problem. Fortunately, looks like you're further towards resolution than I am. Is new carpet included in the $4000 price tag? Did you look into any other materials than aluminum for the replacement? I'd hate to repeat the process again down the road. Did you consider doing the repair yourself?

                    I'm going to call around some marine repair shops to see they can provide me a quote. Not sure I'd want to shell out another $4000 bucks for the repair since I bought the boat for around that price last summer. Its a shame it only lasted 1 season before having to do major repair.

                    I'll update the thread as I find out more. Feel free to do the same.

                    Comment


                      #12
                      Mariner wrote:
                      Since you have an OB you may want to abandon the belly tank for now and run this season with regular OB portable tanks.

                      That buys you time while you decide if it's cost effective to rip out the old tank.
                      That's a great suggestion for alternative solution during the interim. I'm going to look into this as well. It doesn't seem too difficult to figure out. I have 3 hoses running to my gas tank, assuming that's pretty standard. 1 hose is running from the fuel intake to the tank, 1 hose is running from the tank to a vent, 1 hose is running from the tank to a fitting to where the hose/bulb is located to prime the motor. I can't see any visible leaks from these 3 hoses / 6 connectors. I assume portable tanks would have 3 hose connectors as well and I'd just bypass the damaged tank. Is this correct?

                      Comment


                        #13
                        I wonder how similar my boat is in comparison to your pictures. I'm trying to figure out if this is something me and a buddy could handle. Problem is I don't know what's underneath the deck to determine where I need to cut.Anyone have some advice?I figure if I'd incorporate some sort of access panel in case I ever needed to check out that area again in the future.

                        Comment


                          #14
                          Hi 95Bayliner,We considered putting in a hatch, but since the only item that you can't reach is the gas tank (which is now brand new and has an epoxy coating on the bottom and the sides and appropriate tie downs) ~ it was recommended by more than one shop as not to damage the integrity of the hull to have it resealed completely without an access panel...made sense to me.The live baitwell had issues ~ the hose connection on the bottom was loose so the shop replaced the hose and glued it back. I'll post the latest pics....

                          [img]/media/kunena/attachments/vb/662863=25253-boat 1.jpg[/img]

                          [img]/media/kunena/attachments/vb/662863=25254-boat 2.jpg[/img]

                          [img]/media/kunena/attachments/vb/662863=25255-boat 3.jpg[/img]

                          [img]/media/kunena/attachments/vb/662863=25256-boat 4.jpg[/img]

                          [img]/media/kunena/attachments/vb/662863=25257-boat 6.jpg[/img]C legs

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