Can't get fuel tank out of my Grady White Tournament 19...

[proftomda]

Greetings All:

My winter 2011-2012 project is to remove the fuel tank on my 1992 Grady White because of suspected leak. Everything has been removed and tank is empty of course. Problem is that the tank measures 64" long and the tank opening is 62.75 inches. I have already cut 3/8" off the front and rear tank cover flanges and only 3/4" remain on those flanges but still the tank is 1.25 inches longer than opening. I have tried all matter of tilting, rocking and positioning the tank all the way aft and forward and the best I can do is reduce it down to 1".

Basic math says I will have to: 1. cut away and virtually eliminate the front and rear tank cover flanges and weaken structural integrity or 2. cut tank apart and remove in pieces.

Anyone with experience in either of these areas? I have searched posts for 2 days and the worst situation was the tank was 1/2 longer so the flanges only had to be trimmed 1/4" on either end.

Thanks

 

[Woodonglass]

Re: Can't get fuel tank out of my Grady White Tournament 19...

I would think in your case especially, pics would really help everyone on here to help you with your issue. There's a link in my signature line below that tells you what to do to post your pics.

 

[proftomda]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Here are some pics. Its my first attempt at pics so hope its okay.

One of the pics shows a 2" distance from the front lip of the tank opening to the forward bulkhead. Don't let the black shadow under lip fool you into thinking the lip of the tank is directly under flange! One of the pics shows a 1" distance from the rear lip of the tank opening to the rear bulkhead. In one of the pics, I positioned the tank hard against the rear bulkhead and ran a tape measure straight down as a straight edge to show the front of the tank about 1" forward of front lip of opening. If I then tilt the front of the tank up, I can reduce that distance to 3/4" but no less. The remaining pictures show the tank and the lip reduced down to slightly less than 3/4".

 

[Woodonglass]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Do you have access to the bulkheads in front or behind the tank from under the deck? I'm just thinking that if you did, you might remove one of them which would allow you to slide the tank back or forward enough to get her out. IMHO it's either that our cut the opening large enough for removal. I am not familiar with this boats overall construction so I'm just shooting in the dark.

 

[robert graham]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Maybe just assume that the tank is bad, cut it up for removal, then replace it with a slighly smaller tank? The tank is almost 20 years old and may well be ready for replacement. My brother-in-law has a set-up almost the same as yours, replacing a plastic 60 gallon tank with a 50 gallon aluminum tank. He's rigged his with a stainless steel drain, valve and pipe plug to the bilge area(it's an outboard)...I doubt this is coast guard approved, but it will allow him to drain water out of fuel tank into bilge, then out the back of boat into a bucket. Stainless drain valve plus pipe plug should give him a reliable drain system. Good Luck!

 

[sasto]

Re: Can't get fuel tank out of my Grady White Tournament 19...

It appears your tank was installed before the cap/deck. Can you cut out the flange and remove the tank. Another flange made of fiberglass can be tabbed back in.....or screw some in (up) aluminum.

Good Luck!

 

[oops!]

Re: Can't get fuel tank out of my Grady White Tournament 19...

what is that in pic one?....is that a gussett that goes across the top of the tank....?

sasto is correct......the tanks was installed before the deck went on.... it looks like your deck is actually a liner...(the cap and deck are one) you could cut the flange as sasto mentioned....then slide and shimmy out the tank......or you could cut a bout a foot back of one end.....keep the cut out.....and glass it back in place.....if you do it right....no one will know.

 

[proftomda]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Thanks for replies everyone.

All bracing and wedges have been removed. Empty tank flops around in compartment but just too long. Its funny because I have seen posts about the tank being perhaps 1/2" longer but mine was 1 3/4 inches too long, now 1 1/4 inches too long. Yes, Grady White installs the tanks and bracing before the upper cap is installed.

I have bee in contact with the factory and only info they can provide is to cut as much flange as needed to get tank out and then to use pressure treated lumber screwed into bulkhead as a replacement for flange. They recommend having a smaller tank fabricated to replace original tank. I have much heartburn cutting the flanges out to the point of considering cutting the tank apart inside the boat but concerned about it going Boom.

 

[fishrdan]

Re: Can't get fuel tank out of my Grady White Tournament 19...

If you are replacing the tank anyway, I would cut out the old tank and leave the fiberglass intact. No reason to do a fiberglass repair if it's not necessary.

Here's how I'd remove the tank and I'd like to have others chime in if they think it's a crack-pot idea or they have things to add. Close off all fittings and drill several 5" holes with a hole saw, 2-3 holes fore and aft, and one in the middle there are bulkheads in the tank. After cutting a hole, tape it off with duct tape so gas fumes stay in the tank, then cut the next hole. Have fan(s) running to blow any stray fumes out of the boat. Once all the holes are cut, drain the remaining fuel and clean the tank with a good degreaser, SimpleGreen or Dawn wish washing liquid. Plumb a fan and some dryer hose into the tank (duct tape), then let the fan run for a day or 2 so any residual fumes evaporate, fan needs to sit outside the boat while running. After the tank is dry, go to town cutting the tank out, jig saw, tin ships, air nibbler, etc..

Before doing any of this I would make good drawings of the tank and take pictures so the welder can place the new tank's fittings in the correct spot. So the fittings will connect to fuel hoses properly.

 

[Bondo]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Ayuh,... I think I'd just cut up the tank, 'n go in with abit smaller 1....
Probably rebuild the flange with glass, instead of the screw idea too...

For cuttin' it up,... an air Nibbler is just the ticket...
Aluminum don't spark, 'n an air powered tool don't have Electricity either...
You could start at the fuel sender hole, 'n not even have to drill 1 to get started with the Nibbler...

 

[proftomda]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Thanks everyone for the input...

The tank has been drained for about a week now and I decided to take today off working on boat so I can be clear headed about which way to go. I really don't want to cut up the deck but i really don't want an explosion either.

I have an air nibbler, and I can certainly get a hole saw for metal. I'm just cautious and asking for input from anyone that's been here before.

Once again, thanks for all input.

Prof

 

[proftomda]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Its out...

I ended up cutting the thank into 5 pieces and removing. Of course I ventilated as best I could. I started by cutting a hole big enough for my arm to go thru with a pneumatic zizz wheel. Then I reached inside and washed the inside with dawn detergent and water. After drying, I went to work with the zizz wheel on the front of the tank. My plan was to cut out a section of the top and side of the tank, then bend the forward edge back and lift it out. But it was still too long as the bottom edge of the front of the tank wouldnt clear. I ended up cutting the entire front end of the tank off.

Now that thats done, anyone with a Grady Tournament that has installed a slightly smaller tank and if so, what were the dimensions?

 

[Bondo]

Re: Can't get fuel tank out of my Grady White Tournament 19...

Its out...


Now that thats done, anyone with a Grady Tournament that has installed a slightly smaller tank and if so, what were the dimensions?

Ayuh,... A tape measure will tell ya how much room ya got to work with,...

'n I'd bet These guys probably have a plastic tank that'll fit...