Reply
 
Thread Tools Search this Thread Display Modes
 
Old 03-10-2021, 05:24 PM   #1
Lieutenant
 
Join Date: Jun 2013
Location: Sarasota/Bradenton FL
Posts: 66
Default Fuel Tank Replacement 2003 2400 SCR

I have figured that Maxum set the fuel tank on saw horses and built the boat around it. My tank started leaking after 18 years. Probably a combination of ethanol fuel and condensation after residing in FL it's entire life.


Am looking for suggestions from anyone who have encountered this and how the replacement was performed.


Luckily I have a 15' Logic CC for fair weather boating.
__________________

SRPATTON is offline   Reply With Quote
Old 03-10-2021, 07:03 PM   #2
Lt. JG
 
armbar's Avatar
 
Join Date: Nov 2020
Posts: 40
Default

https://youtu.be/IeveiETNHUQ here the replacement...it's a creezy work!But I have the same problem..and I think I do it!!
__________________

armbar is offline   Reply With Quote
Old 03-10-2021, 08:26 PM   #3
Admiral
 
mmwjr's Avatar
 
Join Date: Feb 2012
Location: Essex, Maryland
Posts: 8,533
Default

Quote:
Originally Posted by armbar View Post
https://youtu.be/IeveiETNHUQ here the replacement...it's a creezy work!But I have the same problem..and I think I do it!!
Removing the midberth window is a great idea as one typically has to pull the engine and cut out the bulkhead in most cruisers like this.
__________________
1997 2400 SCR
5.7 Vortec / Bravo 2

Mike
mmwjr is offline   Reply With Quote
Old 03-11-2021, 02:22 PM   #4
Lieutenant
 
Join Date: Jun 2013
Location: Sarasota/Bradenton FL
Posts: 66
Default 2003 2400 SCR Fuel tank replacement update

My 70 gallon fuel tank was too large to fit through the aft cabin window so I ended up cutting out the cabin floor in a 40" x 46" cut. Removed the bulkhead in front of the engine. There were a lot of accessories attached to that but they all came out with a phillips screw driver and all the wiring and plumbing was flexible enough just to move enough out of the way. By the way, the floor and bulkhead were made of 5/8" plywood so it took less than an hour to accomplish that. The tank had fiberglass poured in the back corners but I cut that out with a metal blade on a sawzall.


Remember safety is paramount here so after pumping out all the gas and filling it with water. Rinsing the bilges of any gas. And then ventillating with a fan. Safety glasses, long sleeve shirt, pants, N95 dust mask, and a fire extinguisher are a must.


Now in the process of draining the water and rigging up a come along to pull the tank.
SRPATTON is offline   Reply With Quote
Old 03-11-2021, 03:12 PM   #5
Lt. JG
 
armbar's Avatar
 
Join Date: Nov 2020
Posts: 40
Default

Have some photos?...good work!!
armbar is offline   Reply With Quote
Old 03-11-2021, 05:54 PM   #6
Admiral
 
mmwjr's Avatar
 
Join Date: Feb 2012
Location: Essex, Maryland
Posts: 8,533
Default

Quote:
Originally Posted by SRPATTON View Post
My 70 gallon fuel tank was too large to fit through the aft cabin window so I ended up cutting out the cabin floor in a 40" x 46" cut. Removed the bulkhead in front of the engine. There were a lot of accessories attached to that but they all came out with a phillips screw driver and all the wiring and plumbing was flexible enough just to move enough out of the way. By the way, the floor and bulkhead were made of 5/8" plywood so it took less than an hour to accomplish that. The tank had fiberglass poured in the back corners but I cut that out with a metal blade on a sawzall.


Remember safety is paramount here so after pumping out all the gas and filling it with water. Rinsing the bilges of any gas. And then ventillating with a fan. Safety glasses, long sleeve shirt, pants, N95 dust mask, and a fire extinguisher are a must.


Now in the process of draining the water and rigging up a come along to pull the tank.
The video didnít clearly show it but if you look closely he removed the window assembly to get the tank out. This was also a 2400 SCR with the 70 gallon tank.
__________________
1997 2400 SCR
5.7 Vortec / Bravo 2

Mike
mmwjr is offline   Reply With Quote
Old 03-11-2021, 07:27 PM   #7
Lieutenant
 
Join Date: Jun 2013
Location: Sarasota/Bradenton FL
Posts: 66
Default 2003 2400 SCR Fuel tank replacement update

I was able to snake the fuel tank out between the bulkhead and engine by lifting, sliding, more lifting and finally it was standing up.


I had to remove the outdrive gear lube resevoir, remove the rear seat, and disconnect the lift rods on the hatch and stand the hatch straight up. (i do this anyway when performing any maintenance on the engine)



Took the tank to Sunrise Marine Tanks in Venice FL for measurements and a new one will be ready next week. The going price is about $10 per gallon.


All of the corrosion on the old tank was exterior where the tank set on stringers. The new one will be primed and coated.
SRPATTON is offline   Reply With Quote
Old 03-16-2021, 01:48 AM   #8
Lt. JG
 
99maxum211's Avatar
 
Join Date: Oct 2020
Location: Brooklyn ny
Posts: 47
Default

I cut the wall between the aft and the engine bay..tank was out within 45 min
__________________
1999 Maxum 2400 SCR 5.7 Merc Alpha 1 Gen 2
99maxum211 is offline   Reply With Quote
Old 03-16-2021, 11:25 AM   #9
Lieutenant
 
Join Date: Jun 2013
Location: Sarasota/Bradenton FL
Posts: 66
Default

Great job! Picked up my new tank yesterday and I'll be running again in a couple of days.
SRPATTON is offline   Reply With Quote
Old 04-06-2021, 09:56 AM   #10
Lt. JG
 
armbar's Avatar
 
Join Date: Nov 2020
Posts: 40
Default

extraction performed successfully .. now the new... tailor-made steel!!!
Attached Thumbnails
20210326_124208 (FILEminimizer).jpg   20210326_124215 (FILEminimizer).jpg   20210330_112525 (FILEminimizer).jpg  
armbar is offline   Reply With Quote
Old 04-06-2021, 11:48 AM   #11
Admiral
 
mmwjr's Avatar
 
Join Date: Feb 2012
Location: Essex, Maryland
Posts: 8,533
Default

Did you remove the midberth window and take the tank out through that hole?
__________________
1997 2400 SCR
5.7 Vortec / Bravo 2

Mike
mmwjr is offline   Reply With Quote
Old 04-06-2021, 01:56 PM   #12
Lt. JG
 
armbar's Avatar
 
Join Date: Nov 2020
Posts: 40
Default

Yes I removed the window, and I let the tank out, but first, I cut it in half and it came out well.Now I'm going to a craftsman to rebuild it in steel "tailormade"..
__________________

armbar is offline   Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Powered by vBadvanced CMPS v3.2.3

All times are GMT. The time now is 02:42 AM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2021, vBulletin Solutions, Inc.