might be time to replace a built in aluminum fuel tank

[bigdogg1]

Hi there,

I have a built in tank that measures ~ 6" x 2' x 9' long. It runs straight down the middle from stern to mid point of the seating area in the cabin. I can see that it is held in by 8 bolts to the boat frame (8 per side).

My problem is that it looks like the aluminum floor will need to be cut in a 2 foot strip to get to the bolts and to remove the tank.

Although I do not mind cutting a deck access panel to re and re the tank, I am not too excited about running a blade/grinder disc around gas fumes (there is no danger of hitting the top of the tank as there is about a 4" breather space.)

Is this doable in an open, ventilated area or should it be left to a shop. I am looking of tips on how to safely cut through the floor if possible and if not, can anyone suggest an aluminum cutter in the Parksville area. Thanks in advance!

 

[SteelyDan]

The aluminum won't spark. Use a skill saw or a jig saw not a zip disk. I'd set the depth of my saw blade 1/8" past the thickness of the floor and skill saw it.

 

[windsurfer]

Aluminum doesn't make sparks when cut with a grinder, so the concern would be the electric motor in the grinder making sparks. Unless there is a large concentration of fumes you should be fine. ventilate well with a fan.

 

[windsurfer]

The aluminum won't spark. Use a skill saw or a jig saw not a zip disk. I'd set the depth of my saw blade 1/8" past the thickness of the floor and skill saw it.

I agree. Skill saw it. A carbide tipped blade works well.

 

[bigdogg1]

Great advice - thanks!

Now for the reconstruction part. Once the rectangular floor piece is cut away (just over 2' x 6'), how would you suggest I reattach it since there is only empty space below the cut lines? I thought about creating a small ledger that attaches to the aluminum stringers set just deep enough to create a flush floor when the cut piece is put back. I would then look for transition pieces or other to fill the gaps.

Any other ideas are appreciated.

Thanks.

 

[noluck]

backing bar and a tig welder, weld the cutout back in

 

[spring time]

If you are really worried about fill the tank up with water, but there should be no spark with aluminum

 

[daddystoy]

When I re and re'd my gas tank last year I had to cut up the fiberglass floor to get at the tank. Of course that was a dirty ugly job! I replaced the covered area over the tank with a removable piece that is fiberglassed and gelcoated. Looks neat and tidy. Now if I need to get the tank out in the future or get access to fuel sender I remove 10 screws and I have complete access to the tank.