Replacing Gas Tanks In Older Proline Boats

Replacing the gas tank in a 1989 Proline boat can be a challenging task. While some boats have accessible compartments that make it easier to work on, others may require cutting the deck to remove and replace the tank. It is important to inspect the gas tank and lines for any signs of leaks or corrosion, especially if the boat is older. In some cases, an external gas tank may be considered as a temporary solution until a new internal tank can be installed. When working with gasoline, it is crucial to take safety precautions to avoid sparks and potential explosions. Seeking professional help or advice from boating forums can be beneficial for those who are unfamiliar with boat maintenance and repairs.

How to identify a leaking gas tank

How to Identify a Leaking Fuel Tank

Identifying a leaking fuel tank in a boat is a serious issue, and it could be life or death. There are several signs to look out for to catch a fuel leak. Firstly, if you notice a smell of fuel when you open up your boat, this could be a sign of a leak. Open up the bilge, the lowest point in your boat, and check for any fuel that may have collected there.

Another sign of a leaking fuel tank is if you notice puddles of fuel around your boat after it has been parked. Additionally, you may observe that your boat's fuel consumption is higher than normal, indicating a potential leak.

If you suspect a fuel leak, you can use test kits that allow you to add dye to the fuel, run it, and inspect the engine and bilge with a light to identify any leaks.

It is crucial to act quickly if you detect a fuel leak. Open all hatches to create airflow and disperse fumes, reducing the risk of fire. Turn off the fuel valves to stop the fuel flow and help isolate the problem. If the leak persists, the fuel tank is likely the source.

Remember, gasoline vaporizes at a lower temperature than diesel, so both types of fuel pose a risk of igniting and causing an explosion. Take the necessary precautions and consider seeking professional help to address the issue promptly.

How to drain a gas tank

To drain a gas tank in a 1989 Proline boat, you will first need to identify the location of the tank and determine if it is easily accessible. If the tank is located in a compartment with a deck seam, such as around the console, you may be able to access it without having to cut into the deck.

If the tank is not easily accessible, you may need to create an access point by cutting into the deck. Before doing so, ensure you have the appropriate tools and safety equipment, including eye protection and gloves, as you will be working with flammable liquids. It is also recommended to clean the bilge with soapy water and remove any gas residue from the surrounding area.

Once you have identified the location of the tank and determined the level of accessibility, you can begin the process of draining the gas. If there is a leak in the tank, as described in your post, it is important to take extra precautions to ensure your safety and prevent any potential ignition of fumes. Ensure the area is well-ventilated, and do not use any power tools that may create sparks.

To drain the gas, you can use a cheap 12V fuel pump to pump the gas out of the tank and into cans or another suitable container. This process should only take around 15 to 20 minutes. If you are unable to access the tank directly, you may need to remove the fuel sender to create a larger opening to work with. Mark the placement of the sender before removal, as the screw pattern must be replaced in its original location.

Once the gas has been drained, you can proceed with cleaning the tank and making any necessary repairs or replacements.

How to clean a gas tank

To clean a gas tank, you will first need to drain the tank of any remaining fuel. This can be done using a 12V fuel pump to pump the fuel out of the gas line into cans. Once the tank is empty, clean the bilge with soapy water and use a hose to spray inside if you can reach. You can also use a mixture of dawn soap, awesome, and water, followed by bleach, to get rid of any lingering gas fumes.

If your tank is clogged, you can reach through the sender hole to remove the screen or filter on the end of the pickup tube. Be sure to mark the placement of the sender before you remove it, as the screw pattern is not evenly spaced and it must be replaced in its original location.

If your tank is corroded or leaking, you may need to replace it. This can be done by pulling the deck cap or cutting the deck around the tank. If you choose to cut the deck, you will need to reglass it afterward. Be aware that if the internal flotation foam in the hull is soaked with leaked gas, it must be removed with hand tools to avoid the risk of sparks.

To prevent corrosion and prolong the life of your gas tank, you can coat the outside with epoxy. This will give the tank extra protection against corrosion and is recommended by experts.

How to remove a gas tank

Firstly, it is important to note that removing a gas tank can be a challenging task and may require multiple people. It is also crucial to take safety precautions as you will be dealing with flammable substances. Ensure you are in a well-ventilated area and disconnect the negative battery terminal to reduce the risk of sparks.

Now, let's begin the process:

• Drain the gas tank: Siphon or pump out as much gasoline as possible from the tank. You can use a hose to drain the gas through the transom drain hole.
• Access the gas tank: Depending on the boat's configuration, you may need to remove certain components to access the tank. This could include removing the leaning post, opening access hatches, or cutting a hole in the deck. For the 1989 Proline boat, it seems that there is a small circular access hatch behind the leaning post.
• Disconnect fuel lines and connections: Before removing the tank, carefully disconnect all fuel lines, hoses, and connections. Make sure to catch any remaining fuel that may spill out.
• Remove the gas tank: With the fuel lines disconnected, you can now remove the gas tank. This may require lifting or sliding the tank out, depending on how it is mounted. If the tank is corroded or damaged, use appropriate safety gear, such as gloves and eye protection, to handle the tank.
• Clean the area: Once the tank is removed, clean the surrounding area, including the hull, with soapy water to remove any gasoline residue. Ensure the area is thoroughly dried before proceeding.
• Inspect for damage: Take this opportunity to inspect the area for any signs of corrosion, leaks, or damage that may have caused the issue with your gas tank. Address any necessary repairs or replacements before installing a new tank.

Remember to consult a professional or a boat repair manual for more detailed instructions and safety guidelines.

How to install a new gas tank

Firstly, it is important to note that gas tanks are usually located in the boat's compartments, which can be accessed through a deck seam or a deck hatch. Before beginning any work, ensure you have the correct replacement tank for your boat, which can be found by checking the plate on the tank near the sending unit or fuel line out.

Next, you will need to remove the old tank. This may involve pulling the deck cap or cutting the deck around the tank. If your boat has accessible compartments, you can remove the old tank through the deck seam. If not, you may need to cut the deck to create an opening large enough to remove the old tank.

Once the old tank is removed, clean the area thoroughly, paying special attention to any gas residue. You can use soapy water or a mixture of dawn soap, awesome, and water to clean the bilge and any other areas that gas may have gotten. Ensure to also clean any gas-soaked internal flotation foam in the hull with hand tools, as power tools could give off a spark.

Now, you are ready to install the new gas tank. Follow the manufacturer's detailed installation instructions carefully. Pay special attention to any instructions regarding grounding, venting, pressure checks, load distribution, and insulation, as these are crucial for safety and proper function.

Finally, after the new tank is installed, you will need to reglass the deck if you had to cut it to remove the old tank. This will ensure that your boat is sealed and ready for safe operation again.

Remember, replacing a gas tank can be a labour-intensive and costly process, but it is essential to prolonging the life of your boat and ensuring your safety while out on the water.

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