1992 Trophy W/A cuddy fuel tank leak.

[trophyjim]

Hi all,

I have 1992 Trophy W/A Cuddy that has a definite fuel tank leak. I have tested and verified that none of the hoses are the problem. I have been trying to find some information about doing this job myself.
I figure that measuring several times first before cutting is best. What is the best kind of saw blade needed to the do the job without damaging the deck too much? I was planning on using a circular saw with no larger than a 7" blade and setting the depth as required to ensure that I will not cut through any stringers or bracing. What depth would that be? I was thinking no more that 1 1/2 inches. Also I was planning on cutting the deck piece out using a 45 degree cut. My thinking was that this would possibly eliminate the need for installing any bracing around the cut. Does this sound feasible or would it still be necessary to brace the opening before re-installing the cut out?
This would be my first tank replacement and any pictures, information from the forum would definitely help.
I also saw on Bayliner Owners Forum where someone actually pulled the cap and replaced the tank. I do not have access to an A-frame lift or similar lift to remove the cap, so cutting the deck is the only option.
Please feel free to give all information.

Thanks,

Jim

 

[Bondo]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Ayuh,... Welcome Aboard Jim,....

By the sounds of yer problem, I'm movin' this down to the hull repair forum for ya,...

Those guys know their glass, 'n hull structures,...

 

[Mike Lammert]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Hello Jim! Welcome to the forum. If this were me, I would drill a core sample hole. That will tell you how much and what material it is made of, so you can set your sawblade that deep and not cut anything you don't want to cut. I would use a carbide tooth saw blade. As for beveling the edge, this should work if the deck is made of something pretty thick....Good luck with it, you can find some of the best advice in the world here, as well as down to earth folks willing to help!

 

[chriscraft254]

Re: 1992 Trophy W/A cuddy fuel tank leak.

First off, make sure the fuel is out of the tank before you start running any type of power tools around it with fumes in the air. All it takes is one spark in the right location to make for a bad day.

I'm assuming you have an access panel or round inspection plate somewhere over the tank area, you can get your depth setting there. Post some pictures and we will be able to help you better..

 

[trophyjim]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Thanks for the welcome. I do have an access hatch. It is a round 6 inch diameter plate. It is where the sending unit is accessed. I will check the thickness of the deck. What would be considered a minumum deck thickness for the angled cut idea.

This tank started leaking summer 2010. I removed the gas (that didn't leak out on the road) with a hand pump.I have been using a Moeller 26 gallon plastic tank to at least get out and enjoy my boat. But now since winter is here, I figured I would like to tackle this job.

Some people are saying I should attempt to remove the CAP. This would require removing the engine, rub rail, and a b-zillion screws right?

What is the consensus of the forum? Cut deck or remove Cap?

Thanks.

Jim

 

[Bondo]

Re: 1992 Trophy W/A cuddy fuel tank leak.

What is the consensus of the forum? Cut deck or remove Cap?

Ayuh,... Cut the deck,... It's composite, 'n easily repaired....

I like yer angle cut idea, it might work....
Glassin' in under cleats holds the elevations abit better though I think...
It helps make up for the saw's kirf thickness...

 

[Boston Mike]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Hi Trophy Jim,my Trophy is 10 years older and I've got same project going on. Cutting deck this week. 45 Degree angle is something I've thought of as well,when I make the cut. When I put it back together I plan to install a cleat around the perimeter or span a stringer of sorts to span under the deck that'll be glassed in. I figure the end grain of the plywood will need to be treated with epoxy,resin or whatever to help prevent moisture from wicking into the end grain.

Before I make coffin cover cut though, I'm cutting in a smaller access hatch that'll be sealed with O-ring and that'll allow better access than a 6"porthole hatch. This should help allow access in the future what is now a "buried" portion of the boat.

I look forward to how you progress.

 

[mxcobra]

Re: 1992 Trophy W/A cuddy fuel tank leak.

you dont need to remove the cap.
just cut the deck out and replace the tank
look real close their may even be a seam under the glass in the plywood were you need to cut

 

[GT1000000]

Re: 1992 Trophy W/A cuddy fuel tank leak.

what the someone report this glumguigo vires crap

I sent a PM to Bond-o

 

[Mike Lammert]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Wow, thats the wierdest thing I've seen happen on here... Sex dating huh?

 

[Bondo]

Re: 1992 Trophy W/A cuddy fuel tank leak.

I sent a PM to Bond-o

Ayuh,... I got it, but JB beat me to smitin' the spammer,...

Credit, where credit is due,...
Thanks JB...

 

[GT1000000]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Uh, thread title is still messed up...see previous posts...this one came up OK...

 

[Bondo]

Re: 1992 Trophy W/A cuddy fuel tank leak.

Uh, thread title is still messed up...see previous posts...this one came up OK...

Ayuh,... I Think I fixed it now,....