Fuel Tank dimensions for purposes of calculating remaining fuel volume

[barrylab]

That's what I thought until I took the tank out. Had a previous owner painted the tank I would have been even more convinced I was OK.
If you look at this picture:
http://s1261.photobucket.com/user/barrylab1/media/Relentless/Fuel%20Tank%20R%20R/Tank%20Removal/IMG_0070.jpg.html?sort=3&o=3
you can see the corners had rust much worse than the others. The tank sat on plywood which held moisture, and accelerated the rusting process. I decided to replace it with an Aluminum replica, and when I brought the old tank to the fabricator, it began to leak the few ounces of diesel left in the tank. It was a disaster waiting to happen.

[PeteW]

Thanks for posting those pictures of the original steel tank. I'm curious how you got it out in one piece.  I did not think that was possible.  Do you have the outside dimensions from the fabricator ?

It's got a mostly a flat bottom with a radius at the deep end that is somewhat insignificant in calculating volume. So the calculations for volume should work well. But the filler and dipstick opening is several inches up from the deep end.

Pete

[barrylab]

I had to remove the engine and have it rebuilt. While it was out, I pumped the tank into a 55 gal drum, detached the connections and it came out over the plywood box without too much swearing.

I had a new tank built to the dimensions Dale gave me in a .dxf file, and it was an exact replica.
I had it built out of 0.125" 5052 marine grade aluminum, then painted it with zinc chromate primer and an epoxy two part over that.
I then replaced the plywood under the tank with acetal and machined some acetal standoffs for the staps I'm holding it down with (stainless).

I tried posting the .dxf, but this site doesn't like attachments so here's the link to the photos including a screen shot of the .dxf

http://s1261.photobucket.com/user/barrylab1/library/Relentless/Fuel%20Tank%20R%20R/Tank%20Install?sort=3&page=1

[SVJourney]

Thanks for the drawing Barry!  I was planning to remove the eng and change the tank in New Zealand this year, so having the drawing really helps to shop out a bid before I rip it out and lug it around for a template.

Can I ask how much you paid for fabrication as a reality check on how much I should shell out?

Cheers!
Wayne

[barrylab]

Thank Dale (i.e. Maruska).
He put it together back when he had time to do these things. It sure came in handy for me.

Unfortunately I live near Boston, so everything is outrageous. I paid $620.00 to have it built to my specs. I've heard others say they had it done for $400.00, but that was in Texas. Be careful with the fittings. I tried anti-seize materials, but the brass to aluminum junction at the tank kept leaking air. I switched to a Nylon fitting there, and it stopped leaking. I had to ground the fuel solenoid so the rest of the fuel system wouldn't need to rely on the engine ground, but it's working well now.   

[PeteW]

I got around to measuring my tank. And using the dipstick calculator, turns out its only 20 gallons. I can't go anywhere on that. I measured the sail locker opening it appears I might be able to fit something in the range of 25 x 30 x 13 through that opening. That would get me up to around 42 gallons.

Anybody swapped out their tank with the motor in place? Would like to hear what you were able to get in there.

Thanks,  Pete

[P69]

Pete,

I replaced my tank with the engine in place, but I removed the nav station and the bulkhead separating the nav area from cockpit locker. I brought the tank fwd and out the companion way hatch. Even if you could get the tank out of the locker (which you can't), you might not be able to get it up and past the fore and aft stringer that runs from the rudder post support to just fwd of the engine (one on each side).  I had to cut mine away and replace it once new tank is installed.    If you boat is one of the few with a quarter berth, you can remove it, then pull the tank fwd around the engine.

http://s1278.photobucket.com/user/scherzoja/media/New%20fuel%20tank/P5109331_zpsqjaoor1d.jpg.html
http://s1278.photobucket.com/user/scherzoja/media/Quarter%20Berth%20and%20Nav%20desk%20rebuild/3_zpsttk7dgbk.jpg.html

Good luck Pete.

For those of you who are considering replacing tank with one of same size, you might want to consider shortening to 25" and widening to 29". This maintains the ~50 gallons, but gives you more room between tank and engine, enough to get you head between the two  and it makes work on that part of the engine much easier. Just be sure you can get that new dimension tank in place (between the cockpit supports (those glassed 2x4 posts  at fwd end of cockpit.

[INCOMMUNICADO]

I replaced my fuel tank in 09 via engine removal used mizzen and main halyards set the engine on the gallie sole. I had the new tank made by Florida Marine Tanks (305-620-9030) They made the original tank. The main difference the new tank is aluminum old was steel . I think the old steel tanks outlasted the aluminum ones. So I had the new tank made twice as thick as standard with no fuel gauge sending unit or port. Total Invoice was 529.00. Allen

[SVJourney]

Just replaced our tank in New Zealand.   I removed the engine as I wanted to do a minor overhaul to it anyways, then brought the tank out the companion way.   Replaced with a .125 inch aluminum tank built at the Riverside Drive marina in Whangarei.   We used the drawing that is posted up on this thread and it was totally accurate. Cost was ~&400 USD.

You can see pictures of the removal, including the cabinet cutting required on Dana's most excellent blog:  http://www.galleywenchtales.com/2016/02/heave-ho-out-she-goes.html