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Fuel Tank Leak

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Old 09-03-2018, 04:07 AM   #1

porker is currently offline
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Default Fuel Tank Leak

I have a 97 Talari 209. I am pretty sure my fuel tank is leaking from somewhere along the bottom of the stern side of the tank. Reason being, on the trailer with the bow propped up I am seeing a small but steady stream of fuel pass from the through-hole into the engine bilge. It only stopped when I completely emptied the tank. As a further test I refilled about 1/4 gallon and the leak immediately resumed.

Am I perhaps missing anything or does the above explanation confirm my suspicion?

I am still a bit new to boats. Am I looking at needing to cut the floor open to pull and repair/replace the tank?

The photo attachment provides a little bit of context if it helps (fuel sending unit already removed).
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File Type: jpg FuelTankAccessDoor.jpg (192.1 KB, 23 views)
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  • Old 09-03-2018, 12:08 PM   #2

    pole trick is currently offline
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    Default Re: Fuel Tank Leak

    I would think that the tank has problem on bottom or lower.sides. Aluminum tanks can Crack on welds and can get holes rubbed through them. All your fittings and fill are high on tank. So it must be problem on lower part of tank. How to get it out to replace it..I have no idea. If boat built like my 180. It looks like cutting the floor up is only way out? Pretty sure tank was installed first then floor..sucks..
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    Old 09-05-2018, 06:57 AM   #3

    porker is currently offline
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    My Model: 209 Talari
    My Engine: Volvo Penta 7.4L/SX
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    Default Re: Fuel Tank Leak

    Pulled the tank and confirmed the leak after filling it with water. Overall it was in worse shape than I imagined. There are numerous pits with varying levels of corrosion, mostly on the bottom (see photo).

    What are people doing for replacement tanks? I'm not seeing anything online that has the same dimensions as my 40 gallon. It looks like RDS can custom make an aluminum tank. It also looks like there are some prefabricated plastic tanks that could work but I'll need to take a little bit of a capacity reduction.

    Also in case it helps anyone else I threw in a picture of the deck after removing the panel that covered the fuel tank. In my case I didn't have to cut anything, just needed to find the screws and lift the panel up. I was aided by the fact that the fiberglass/resin that was laid over to protect the deck was in very poor shape on that particular panel, allowing me to find the screws relatively quickly.

    Unfortunately I think I'll have more trouble with the deck repair than anything I have done thus far. The decking on the starboard side has slightly lifted and I am hoping it is well enough to be refastened and re-glassed without having to fully replace the whole deck.
    Attached Images
    File Type: jpg LeakyFuelTank.jpg (144.9 KB, 11 views)
    File Type: jpg RemovedFuelTankPanel.jpg (239.4 KB, 13 views)
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