FUEL TANK REPLACEMENT ... SR 290

CHUCK SR

New Member
Mar 9, 2021
3
Boat Info
'97 SEA RAY SUNDANCER 290
Engines
DUAL MERC 350 MPI, ALPHA DRIVES
WHERE CAN I GET DRAWINGS AND INSTRUCTIONS FOR REMOVAL AND REPLACEMENT OF A FUEL TANK THAT LEAKS GAS ... GENERAL WORD DESCRIPTION OF PROCESS APPRECIATED IF NO REFERENCES OR SOURCES KNOWN
 
Your profile says 97 290. Sundancer? Is it the wide body, late model 97? That one is a 10’2” beam. Or the older style, that’s 9’6”

I ask because I have drawings for the 98 I can find for you. Either way it’s going to be a big job. You’ll probably be best to cut it into pieces from inside the aft cabin and replacing it with a fuel bladder
 
MY 1997 SR 290 IS THE ONE WITH 10'2" BEAM ( "290 SDA") ... BELIEVE THE 1998 DRAWING WOULD APPLY TO THIS HULL... I AM NEW TO THE SEA RAY CLUB ... WHAT IS PROCESS TO COMMUNICATE FURTHER SO WE COULD ARRANGE FOR PROVISION OF THE DRAWINGS ... ALSO, WHAT SUPPLIERS ARE YOU AWARE OF THAT SELL BLADDERS ? THANKS
 
The common way to do this would be to remove the engine and slide the tank backwards and out. I say "engine" because you may be able to get it out without removing both. But don't worry, it's not as big of a job as it sounds, even if you have to remove both. While it would take the first timer longer, for a good "shop" it shouldn't take more than a couple hours. You might consider hiring this part out, then doing the rest yourself.

You can take a look, but I don't think there's going to be enough room to pull it up and forward. You'll get a better idea once you remove the floor panel in the mid-berth.

IF you're going to cut a fuel tank, you better make sure you get all the gas AND the fumes out so you don't blow yourself up ;) But the better long term solution is a new tank.

Florida Marine Tanks is a reputable place to have a new tank made. But also check around with local fabricators/welders.
 
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Thank you ... will be quite a project ... drawings a good start
 
It will be, but the good news is like Dennis said if you get the engines out the tank should slide out over the top of the stringers. I apologize but its been a while since I was in the 290 bilge, I was thinking the stringers boxed in the tank but it should be above the top of them. You'll have to cut away some of that bulkhead but beyond that the "damage" should be minimal.

The tank also isn't terribly large so you should be able to maneuver it out.
 
Removing the engines will give you a chance to check on things you normally would not be able to (or at least not too easily), like the converter and inner transom plate. If the boat has seen a decent amount of salt then also the oil pan, for example.

For the record, I'm not specifically "against" a fuel bladder.
 
Just a thought, I might be inclined to get a CG seal of approval doing this. God forbid something bad happens you don’t need insurance denying the claim down the road.
 
PS house fire in 2014 taught me a lot about permits, insurance, claim denials, etc. it all worked out for me but Thank God the previous owner had pulled permits on a very expensive addition else the ins co was gonna deny the claim.
 
FYI, replacing a fuel tank actually isn't all that uncommon of thing. It's really no different than replacing anything else.
 

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