Tank Removal

Kurtbowman

New Member
Mar 8, 2017
1
Saint Simons Island, GA
Boat Info
Sundancer 420
Engines
3208 cats
1990 Sea Ray Sundancer 420. Diesel 3208 Cat engines.
Developed a leak in the 200 gallon port diesel tank. Can't identify where the leak is. Pumped out fuel into the starboard tank. Question is how do I get the tank out!?
 
Call Sea Ray Customer Service, I personally have never needed to but heard several reports they are very good about answering questions like this.
 
I'd guess cut the deck or remove the engine. Interested to hear how this one turns out.
 
Our 450 developed a leak in both tanks roughly at the same time and you can cut the side hull or pull the deck and engines to replace. The new owner has the deck removed and both motors out and new tanks going in now. Really not that much to the removal had it out in one day.
Something about a brass plug in the bottom of each aluminum tank has caused the electrolysis problem.

Tommy
 
They usually come out by removing the cockpit seating/upholstery, removing the cockpit floor (it bolts in), then if you are lucky and if the tank isn't a weird shape like an "L", you might bet by by removing one engine and transmission, but it may require that both be removed, as well as any other components that are in the way like holding tanks, generator, water heater, etc.
you will need to use a boat yard with the abi;ity to haul out the boat and block it up while the replacement is proceeding. The yard will also need the ability to lift the deck and the engine/transmission.

You will need to contact Sea Ray customer service sooner rather than later. The fuel tanks are produced by Florida Marina Tanks so you will need to get the tank's model and serial number in your boat to begin the discussion with Fla Marine Tanks. The tanks are expensive and horribly expensive to ship.

Good luck with the replacement.
 
Once out, you may want to see if there is a local source to fabricate new tanks to save time and avoid the expense involved with shipping.
Bring him your old one and have them make an exact copy.
We just took out two tanks in my Uncle's 22' Eastern fishing boat in October. It's an outboard boat that had one 40 gallon and one 30 gallon plastic tank buried under the deck. One of the tanks collapsed.
We brought the boat to a fiberglass guy who cut the deck open, removed the old tanks, we found a local guy that makes marine tanks out of aluminum in any configuration you want so we had him make a single 64 gallon for us. After it was installed the Fiberglass guy closed up and refinished the deck as good as new.
The shop we used was lined with tanks in all shapes and sizes that he made for all different boats. It's his only business For a guideline: The price averages out to about $8.00 a gallon and includes all fittings and sender. Your tanks are much bigger so you may get a better price per gallon.
He makes them up by copying yours, or from blueprints, or from drawings, or any other way you can tell him what you want.
Oddly enough there is another shop a few doors down that does the exact same thing for about the same pricing. We picked the guy we picked because our fiberglass guy felt although their work quality was the same, this guy kept to a promised completion date. He told us he was backed up about 2 weeks and that's just about how long it took.
 
Replacing mine now. Engine is out. Waiting for a few warm days to slide the port tank out. I was quoted about ten dollars a gallon to fabricate. Depending on how hard it comes out, I may may it an inch or two smaller to make it easier to go in. The problem thwart concerns me now is the abundance of heavy gauge wires on the port side that don't want to be moved and may crack and or break.
 
Replacing mine now. Engine is out. Waiting for a few warm days to slide the port tank out. I was quoted about ten dollars a gallon to fabricate. Depending on how hard it comes out, I may may it an inch or two smaller to make it easier to go in. The problem thwart concerns me now is the abundance of heavy gauge wires on the port side that don't want to be moved and may crack and or break.

$10.00 seems a bit high. Are they physically taking it off and re-installing it for that number? We paid $8.00 here in the people's republic of NY this past fall but carried them in and out of the shop ourselves. It was about a two week turnaround once we dropped off the old tanks. Then again, there are two shops who do the exact same thing right down the street from each other so that may keep the price a little lower. The price did include all fittings and senders.
We took the opportunity to freshen up the sender wiring and install new fill and vent hoses while we were at it.
 
Last edited:
Sending units included. Removal and installation not included. On another note, Kurt, how are you making out on the removal? Have you made any progress?
 

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