The (dreaded) fuel tank leak - Novurania 550

[Westcoast]

Hi all:

Thanks much for reading this post. Have been searching the archives for folks that have dealt with a leaking in-hull Novurania gas tank.

I have a 550dl and have discovered fuel in the bilge. Hoses check out fine. Sender good. No visible leaks on top of tank.

Gas leaks visibly into bilge when nose of boat is lowered on the trailer.

Suffice it to say, not a happy situation.

Has anyone here dealt with this issue on their Novurania?

A couple things of particular concern are how to remove the tank - especially seeing as how it extends aft beneath the passenger seat and console - both of which are fully fiberglassed right into the floor and gunnel.

Even if I was to cut the floor out not too sure how all that would reattach and look half decent??

I see others have fitted smaller tanks into the old one and gave up on the aft section of the tank. I do rely on that full tank for where Im out often so the idea of losing half my capacity is definitely less than ideal.

This all came to a head yesterday / today so I think Im still working it all thru in my mind.

Will be draining the tank tomorrow and starting to work out a plan from there.

Any experience or sage advice very welcomed!!

Thanks much

[jeffstevens763@g]

You can buy sealing kits but I guess would be too difficult to apply could you cut away some of the tank and fit a bladder inside?

[Westcoast]

Hi Jeff:

I think that is the first step is to explore that sealer. I am looking at one product here in Canada ppl say does work. I think the application would be a best efforts attempt as the instructions talk a lot of prepping the inside and also rotating the tank - both of which are pretty complex given as how the tank is stuck in there. That said I think I could get the bottom pretty decent.

Good call on the bladder - will check that out - would have fill the tank with water presumably and then start cutting out the top. Which should go pretty quick. Thanks much for your thoughts!

[jeffstevens763@g]

Interesting problem I bet there’s others in a similar predicament keep the thread going as you do the repair, bladder seems the best option to keep it easy ish and fuel capacity

[Westcoast]

Thanks Jeff - yes Im certain not the first time - will keep the updates coming!

[Nasher]

Not seen it done on a Novurania, but on both the tanks I've been involved with fixing a bladder turned out to be the easiest option.

Tank sealer usually involves pouring in the sealer and rotating the tank in all directions to coat the inside, not that easy with a RIB of any size, but can be done.

Repairing the tank properly involves taking it out by cutting a large hole in the deck.
Actually, this can be the easiest way to do it and is no doubt the safest as you are not rotating a heavy lump or getting sparks anywhere near anything that might explode.
The tank can be taken separately to a specialist repair company used to working with Fuel tanks.

A bladder can in theory be pushed through a smallish hole cut in the top of the tank, but you obviously need to flush the tank and fill it with something inert before taking a grinder to it - Exhaust gas works if you are brave.

However, as I found to my cost, that hole needs to be made bigger than you think so you can cut out any internal baffle plates welded inside the tank.

[Westcoast]

Hi Nasher

Great info thanks - very appreciated.

Noted on the process.

Any recommendations on fuel bladder providers?

Great stuff

Thanks


R

[cgoing]

Originally Posted by Westcoast

Hi all:



Thanks much for reading this post. Have been searching the archives for folks that have dealt with a leaking in-hull Novurania gas tank.



I have a 550dl and have discovered fuel in the bilge. Hoses check out fine. Sender good. No visible leaks on top of tank.



Gas leaks visibly into bilge when nose of boat is lowered on the trailer.



Suffice it to say, not a happy situation.



Has anyone here dealt with this issue on their Novurania?



A couple things of particular concern are how to remove the tank - especially seeing as how it extends aft beneath the passenger seat and console - both of which are fully fiberglassed right into the floor and gunnel.



Even if I was to cut the floor out not too sure how all that would reattach and look half decent??



I see others have fitted smaller tanks into the old one and gave up on the aft section of the tank. I do rely on that full tank for where Im out often so the idea of losing half my capacity is definitely less than ideal.



This all came to a head yesterday / today so I think Im still working it all thru in my mind.



Will be draining the tank tomorrow and starting to work out a plan from there.



Any experience or sage advice very welcomed!!



Thanks much

Just bought a 530 DL that needs a new fuel tank. Soon as it arrives we’ll be removing and replacing the tank, retubing it and a few other needed upgrades.

[Westcoast]

Hi Chris

Ok good to know - and best wishes with the project. Whats your plan for the tank? If you are retubing are you stripping it right down and cutting it out? Thx much

[Orwell boy]

Originally Posted by Westcoast

Hi Nasher

Great info thanks - very appreciated.

Noted on the process.

Any recommendations on fuel bladder providers?

Great stuff

Thanks


R

Did you see Guyc ,s thread titled flexible fuel storage ?