Replacing the port fuel tank on a Carver 42 ACMY

[CptnMike]

Does anyone have any suggestions on how to do this. I've been told to cut a hole in the salon floor and remove most of the engine. I've also been told to cut a hole in the hull and slide the tank out laterally. Which is the best way to do this; personally I don't have a clue. By the way, I'm not going to do the work myself. This is beyond my capability. Any ideas on this will be greatly appreciated.

[waybomb]

The tank is under the cabinet along the port wall.

When we had our 4207, I took the cabinet face and dividers apart to install a large TV in the cabinet, a home stereo, along with Klipsch speakers. It's not that hard to disassemble, and I would think much easier than taking the engine apart or out. But I would do alot of checking to make sure the tank would come out through the hole you make under that cabinet once removed. Also check what's underneath all of that. You'll want to check the relationship to the tank and the main cabin a/c unit, though I think the genset is right below the a/c unit.

Also, if I recall, the floor structure has a removable hatch above each engine, and an aluminum superstructure holding up the floor and the hatch. I believe you'd have to remove some or all of the structure one that side of the boat. Mine had wireways attached to that structure which could get fun.

I've heard of shops cutting the sides out of older Hatteras boats to replace the stinky Detroits with more modern cats, mans, etc. But I also believe once the engine is back in, the entire inside of the boat is accessible to do the inside fiberglass work. I guarantee you, you will not have the ability to get to the backside of the reinstalled plug to support it properly and re-fiberglass it in. I just don't think you could do it "right" on a 4207 - no room.

EDIT: Just had another thought - could you cut a portion of the tank open and install a bladder? That would probably be cheapest. And it should last a very very long time.

[AaHubb]

I too would look for a bladder solution. You didn't say if you have diesels or gassers, could make a difference on partial removal.

[waybomb]

Another thought - thinking about the engine hatch. There's really not that much to disconnect to get the engine out. The harness should simply unplug, you'll have disconnect the battery leads, exhaust hoses, fuel line, throttle and transmission cables, the prop shaft coupling, and drain the fluids. It would be easier to do this than disassembling the engine for clearance and cutting holes where you really shouldn't be cutting holes.

Remove the carpet, pull the hatch, set up an a-frame over the engine, lift it up, put the hatch back down, some heavy wood, and set the engine down to take some weight off the frame.

Then disconnect the tank and pull it out the stairway.

[AaHubb]

And while the engine is out you will find a half dozen other things to do simply because you can.

[CptnMike]

They are diesel.

[waybomb]

Just use a very strong a-frame hoist. It shouldn't be that bad.
If you needed to do an R&R on the engine, that's what you would do.

[CYO Admin]

I helped pull a large Detriot out of 55 something Sea Ray last year. We used a large aluminum I beam stretch between 2 A frames. We used a heavy duty trolly and come-alongs to lift the engine and trolly it to the back deck where a forklift removed it from the boat, so it's very doable.

The hardest part of the whole process was removing the galley. I'm not saying it was easy, but it's very doable with the right equipment.