Leaking Fuel Tank Repaired

[ZigZag]

Leaking fuel tank repaired : Carver 4207 w/ CAT 3208s.

We repaired the starboard aluminum tank by installing an access plate near the aft end. Gaining access and machining the side of the tank to receive the access plate took more time than repairing the leak itself. Once the access port was ready, we cleaned, patched and sealed the tank bottom on the inside – then closed the access port.

Access was awkward but do-able; the leak (and the cause) were obvious; compared to other methods, the repair was relatively inexpensive; and, we have high confidence in the result. If it is ever necessary, it appears that the same repair could be done on the other side.

Because of poor tank access at the rear of the engine, I began the job by hiring a small mechanic to remove (and eventually re-install) some engine parts -- the exhaust pipe was particularly stubborn. His labor was 6 to 8 hours.

Other than that, I did the work. My part took two weeks and about 40 hours (estimated). The cost of parts, materials and tools (no labor) was under $1000.

Even with the engine parts removed, access is quite restricted -- the job is best done by someone 5’10” / 170-lbs or smaller. It will help if the repair person has considerable experience in multiple areas of boat repair.

If you would like details, send an email request to kreed60950@gmail.com.

Bob

[Dad Joke]

What did you use to repair the leak? Thanks.

[ZigZag]

After multiple etchings of the compartment, pinholes were filled with Marine Tex epoxy (diesel resistant). Then bottom of compartment immediately covered with same to accept a matching 12x 12 x 1/16" aluminum plate (plate bottom also covered). Full cure while pressed with 40-lbs of lead. Then compartment re-etched (to 1" up the sides) with special metal prep for POR-15 sealer. Two coats of POR-15. (POR-15 support says that it bonds fine to Marine Tex epoxy).

Appeared to be a very good job. If the materials are half as good as the manufacturers claim, it should outlive the boat. Especially if we keep future water out.

I think the problem may have been caused by the engine fuel pickup ending 4" off the floor of the tank (factory installation) -- so no water was ever picked up by it (to transfer to the Raycors); and, a rubber extension on the fuel transfer line had completely fallen off -- leaving that pickup about 12" off the bottom -- so again, no water was ever removed.

Good Luck.