Marlow Marine Sales, Inc.

4204 13th Street Court West, Palmetto, Florida 34221
Ph. 941-729-3370  •  FAX 941-729-4955  •  1-800-362-2657
e-mail  sales@marlowmarine.com

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Replacing Fuel Tanks

Leaking fuel tanks due to rust have become enough of a problem that we at Marlow Marine have developed a specialized method of replacing each tank in one piece.  

The common, but out-dated, method was to cut the tanks into several pieces and remove them through the salon floor. Often the existing hatches were not large enough to use as exits so the hatches had to be enlarged. There are several major problems with this method of removal:

• the cutting up of the tanks in the engine room produces a shower of metallic particles which land everywhere and will rust for years to come, leaving your engine room with terrible stains

• inevitable damage to the salon and deck from the many trips by workers to remove the rough pieces of the cut-up tanks and fittings, no matter how careful and conscientious

• the original tank is replaced with two or three smaller tanks, depending on fuel capacity, necessitating many more fittings, with greatly increased chance for leaks while losing the original yacht tankage configuration. Many owners and potential owners consider this alteration a detriment to the value of their boats

• the cost and time involved in repairing damage to the salon can be quite high

• the total cost to do the job in the "old way" is more than the right way

We have done quite a few tank replacements and can complete this task with great expertise and in a relatively short period of time. We do not involve the interior of the boat at all since we cut through the hull directly under the tanks and drop them through the openings. This method sounds radical but with the fiberglass materials and technology available it makes the most sense. Consider the advantages:

• tanks are removed in one piece so  there is little or no debris left in the engine room

• the interior of the boat is not disturbed

• the original tank size and shape can be duplicated with original fittings and hoses being used, maintaining the original configuration of the engine room

• the plug cut to remove the tank is used to fill the opening in the hull, requiring very little fiberglass work while enhancing the integrity of the hull   

• the area of repair will be the strongest panel section in the yacht when complete

Many yachts suffer damaged hulls in normal operation by running aground or hitting objects in their paths. People do not leave their boats as useless because of the damage. Their boats are made whole again with expert fiberglass technology and little thought of the original hole. The insurance underwriters inspect and approve this technology declaring the hull as sound as an original hull.

The series of photos below show the steps we take to replace fuel tanks.

Removal of the cut-out to expose the tank	Tank removed, plug edges prepared for glassing
Technician glassing the plug in place	The glassed plug
	The engineering applied to the designed laminate exceeds the original specification of the builder by a very wide margin. This will be the strongest part of your boat's hull panels. To us, cutting the tanks up inside and replacing them with an altered shape, size and look, is sort of like removing a vital organ and replacing it with an aftermarket replacement that does not work as well as the original, through the throat. It isn't rocket science, it is just good old fashioned craftsmanship in a newer technology.
Ready for new bottom paint and many years of trouble free service.

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This site was updated on 8/25/06