Formula 27PC Transom Work

[Mikeopsycho]

Wow! Nice of Formula to be so helpful! When I pulled my leaking gas tank this year I had to wing it because the boat builder retired and sold out to another builder who quit production a couple years ago. Anyway, my tank was foamed in, the foam got wet because my fresh water tank started leaking (which was also an aluminum tank, foamed in). I didn't know anything about fiberglass work when I started, but thanks to lots of input and guidance from my iboats friends, I managed to get my new tanks installed and everything sealed up and fiberglassed. Just keep asking questions here and you should get all the help you need to get this project done. Good luck.

 

[tpenfield]

Just taking a longer look at the pictures, I can see why they have the aft cabin bulkhead cut up higher (to the height of the Halon extinguisher) . . . it allows the tank to be lifted high enough to clear the engine room bulkhead.

With the tank removed (on your boat), you will be able to tab in and seal the bulkhead much better/easier, than if the tank were to remain. You will also get a good look at the main stringers

It looks like there is about 2-3" of foam all-around the sides and bottom of the tank .

 

[alldodge]

Pulled the hot water tank, removed straps off the holding tank and unbolted all the cables and water lines. In Formula pics they made a real nice even cut through the bulkhead, or at least they cleaned it up to look that way. Think I'm going to cut using a sawzal and a 18V skill saw. Also cut a bit wider on port and even on starboard side. Might make the hole a in pieces and use new to refit later. Don't like using power tools around a gas tank, but know of know other way. Using rags and plugs to close up the holes to keep the fumes to a minimum.

 

[alldodge]

This is how far I got today. All the cables out of the way



Cut it open





Did a bunch of digging but tank will not budge as yet. Have bits of foam everywhere. There is next to no foam on the starboard side. about 2 inches on port and forward sides, and 1/4 inch at the rear. Sure there is plenty on the bottom. Will get back at it tomorrow

 

[tpenfield]

Wow, nice progress. :thumb: Separating the tank from the foam can be tedious and time consuming. Lots of small chunks of foam and trash bags full of the stuff.

I was able to get my tank to 'pop' from the foam along the bottom by using a couple of boards near a corner of the tank to form a wedge. It seems that removing the foam from the sides and ends still leaves it fairly well secured by the foam along the bottom.

 

[alldodge]

Sure need some kind of tool to worm it's way through. Scott mentioned some kind of tool on the end of a drill which has my interest. Will try the wood wedge thing.

 

[jc55]

I'd use an electric chainsaw. I swear by those things now because they don't damage the fiberglass.

 

[kcassells]

I'd use an electric chainsaw. I swear by those things now because they don't damage the fiberglass.

I used a sawsall, claw hammer,various prybars. Cut the foam to varying depths into the foam then cut into "cheese size" pcs. and pullout with claw hammer, after the depth got to deep used long pry bars to go further. Used the rear bulkhead to support my 2x4 and used the old fashioned Egyptian method of leverage. No one else to help me so I was on my own. Tough spot but mission accomplished. Kinda like what I think tpenfiled said. If you have fuel in the tank you need to remove it. For 2 obvious reasons;
A boom boom boom
and the unneeded weight your trying to lift for no reason.












It can be a toughie but this old man did so you will also.

 

[Scott Danforth]

Sure need some kind of tool to worm it's way through. Scott mentioned some kind of tool on the end of a drill which has my interest. Will try the wood wedge thing.

A drill extension and a cup brush in the cordless drill. Got mine at either menards or fleetfarm. I know that lowes, home depot, and even tractor supply and harbor freight have them, however here is link on amazon.
http://www.amazon.com/Vermont-Americ...rill+extension
http://www.amazon.com/Vermont-Americ...ords=cup+brush

I used up to 3 18" extensoins to go into areas to remove foam from difficult to get to areas. chews it down to fiberglass, then just use the shop vac to suck up the crumbs

it is about 1000% faster than cutting it up into chunks and prying out, and much safer than using a chain saw (which will still cut thru fiberglass if you have a sharp chain.....:facepalm

 

[alldodge]

Thanks guys, appreciate it. I can see how a chain saw would work fast but it could also get away from me fast if not careful. I already pump the fuel out, good thing I'm one of the guys you doesn't keep the tank full. Only had about 23 gallons in it and then my fuel pump was froze up, but got it going.

Thanks for clarifying the cup brush, might be able to use it in the back. I do have that kind of brush but not the extension. Currently using an old tire tool with a hook on one end.

 

[jc55]

Good job, it popped right out. I'm going to have to try that cup brush idea...sounds like a good one!

 

[tpenfield]

Good job, it popped right out. I'm going to have to try that cup brush idea...sounds like a good one!

What popped right out :noidea:

 

[jc55]

The tank Dude...what gives?

 

[tpenfield]

The tank Dude...what gives?

Oh, you're talking about Cassell's tank not AllDodge's.

 

[jc55]

LOL!!! I'm sorry TP, I'm the one who's confused. I kind of thought that it came out really quick...my mistake.

 

[tpenfield]

No worries.

 

[jc55]

I think I'm sniffing too many fumes and being sensitive...I'm sorry.

 

[alldodge]

Had me scratching my head also, but no biggie, it's all good

Well dug all around most of the tank and got it to the hull where possible. As before there isn't much and some areas there is no foam on the starboard side. Took deck apes paint scraper and drove it under the stern side of the tank all over. Made wooden wedges and beat the heck out of them driving them under the tank. Asked Archimedes for assistance with my lever, but still waiting on a response (carrier pigeon and scrolls).I was telling the tank your coming out, but the tank was saying oh no I'm not. So far the tank is winning.

Have a 5 ton port-a-power but hesitate using it because the feet are only about 1 1/2 wide, no room to use to pieces of wood. Have about 1 3/4 gap to work in.

 

[tpenfield]

The hull has ribs like my boat (right?). So the cutting tools and wire wheels won't go much further than the first rib you hit as you go under the tank from the stern. IMO it would be important to apply upward force only at the corners of the tank and along the sides to some extent. Anywhere else, I would be concerned about causing damage to the tank, considering the force it may take to separate it from the foam.

With my tank, I was making little progress with the wedges until I hammered a couple of 1x3 wedges in under the tank, which separated it from the foam. It sort of started a chain reaction where the foam began to separate all over. I kept the wedges at the corners of the tank the whole time just to keep some upward force. At times I was concerned about punching a hole in the hull due to the force.

Total elapsed time was about 4 beers before the tank gave up and/or I out smarted it.

 

[alldodge]

Mine also has the ribs. I'm putting the wedges at the edges, mainly on the back side due to I'm unable to get to the other areas. I tried some 1x4 and they went in but not very far with blunt ends, will put some 45's on them. Only had 2 beers and it looks like it will take at least 4, will try again tomorrow. Thanks