Fuel Tank Leak Repair

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E-Sea Going

Veteran Member
Joined
Nov 22, 2018
Messages
54
Location
USA
Vessel Name
E-Sea Going
Vessel Make
Mainship Pilot 430
My 2007 Mainship Pilot 430 developed a fuel oil leak from the main tank. This boat has two saddle tanks the holds about 215 gallons each and gravity flow into a main tank that is 10' long and roughly 30" wide and holds about 350 gallons. The main tank developed a leak. The tank is not easily accessible, and the batteries needed to be removed to have any access point. I found a company, Triton Liners, that actually relines the tank in place. They clean out the tank, remove the baffles, weld in a 3/8" aluminum tank liner inside, and weld it to the original tank from the inside. They pressure test and guarantee the tank for 5 years. I have been very pleased with the work, the professionalism, and the cleanliness of the project.
 

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I'm trying to work out the first photo. It appears the welder is at the far end of the tank welding a seam.

Did they cut of the roof off the old tank to gain access? I am also interested to find out if they repaced the baffles. 350 gallons is a lot of fuel, surley it needs to be in a baffled tank both for stability and agitated fuel being drawn into the fuel inlets. However, that said I am no engineer.
 
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What is the capacity of the tank now? More pics would be interesting.
 
Very curious what they charged per tank to do this work?
 
Also did they pressure test the tank and certify it after the work?
 
They did replace the 4 baffles that were in the tank. The photo taken was actually during the cleaning process. They then welded in 3/8" aluminum to the walls and floor of the tank, creating a tank liner within the tank. There is virtually no loss in volume. The tank was then pressure tested. The entire tank relining took 10 days. It was not cheap, $36,000. No interior work was needed. They cut an opening in the top of the tank, which was exposed in the engine room, and used it to gain access. They then added a manway in its place to facilitate future cleanings. They also replaced all the tank penetrations and valves, as well as the sending unit. I have more photos I can post. The work is certified and guaranteed for 5 years. This is the lower tank; it holds 350 gallons. It is 10' long and 30" wide. There are two additional saddle tanks, each holding 214 gallons, higher up on the outboard thwartship, that gravity drain into this main tank.
 
So interesting.

@E-Sea Going I have a question. Given the scale and price of the work (which I'm not saying was too much), what was the reason for not just cutting up and removing the old tanks and putting in new ones (as a place like American Tank does)?

Not challenging you; just curious.
 
Good question on tank relining vs replacement. I considered the amount of salon disassembly needed to remove a 10' long tank and deemed it too much work. There is a boat in the same yard that is having its old tank cut out and replaced with a tank 45 gallons smaller for ease of getting it back in place. The duration of that job was estimated to be 4 weeks and overall cost roughly the same. I think its very dependent on the location of your tanks and if they are large enough for a welder to fit inside.
 
They did replace the 4 baffles that were in the tank. The photo taken was actually during the cleaning process. They then welded in 3/8" aluminum to the walls and floor of the tank, creating a tank liner within the tank. There is virtually no loss in volume. The tank was then pressure tested. The entire tank relining took 10 days. It was not cheap, $36,000. No interior work was needed. They cut an opening in the top of the tank, which was exposed in the engine room, and used it to gain access. They then added a manway in its place to facilitate future cleanings. They also replaced all the tank penetrations and valves, as well as the sending unit. I have more photos I can post. The work is certified and guaranteed for 5 years. This is the lower tank; it holds 350 gallons. It is 10' long and 30" wide. There are two additional saddle tanks, each holding 214 gallons, higher up on the outboard thwartship, that gravity drain into this main tank.
I'm still a little confused. So they actually cut out the baffles and build a tank inside the original tank? All the seams are on the inside vs. outside on a traditional tank? Seems like a difficult way to do this and the welder must be a gymnast and highly skilled. Not to mention how nasty it would be to have to be inside the tank while welding. I looked at their site and there were no pictures of the process, probably to keep others from figuring out how they do it and copying the business model.
Anyway, seems to be a good solution for some like yourself who want to keep the tank volume pretty much the same and do minimal tearout to accomplish the task.
 
Good question on tank relining vs replacement. I considered the amount of salon disassembly needed to remove a 10' long tank and deemed it too much work....There is a boat in the same yard that is having its old tank cut out and replaced with a tank 45 gallons smaller for ease of getting it back in place.
Thanks for the reply. I figured for such a major job you would have considered the options before choosing.

One note is that on the jobs I have seen (mostly on Grand Banks), the overall fuel capacity wasn't reduced because they go in with stacked tanks (this is all pre-designed so they fit together well).

So they cut out the big original tank and pull it out in small pieces. This is a loud job but doesn't seem to take very long, really. The new tanks are of a size that they can be put in (or pulled out in future) through the existing spaces; they are stacked and interconnected so they act as one tank, and then on you go.

You might lose a few gallons of capacity but essentially they end up the same size. You don't know they are smaller, interconnected tanks in actual usage.

I never knew about the method of building a tank-within-a-tank that you show. Very interesting.
 
Hi E-Sea Going,

I'm gob smacked that you found a welder willing to weld inside an enclosed area, surrounded by flammable items, in an explosive environment. Even in a highly industrial area like Everett, WA, which has strong support to Boeing, the US Navy, and the commercial waterfront, such a welder is non-existent. And there are some VERY, VERY high tech and sophisticated welding shops in this town!!!!

When I attempted a (to me, anyway) simple weld repair on a diesel fuel tank inside my boat some years ago, I was met by a resounding not only NO, but H$%^ NO. Hopefully, Triton's method of method of leak repair was successful, everybody survived the process, and you are back at sea.

And while my opinion of the described process of welding a new aluminum tank in situ is unimportant, all I can say is "not on my watch". Gives me the willies on so many fronts.

Regards,

Pete
 
The tank relining is completed, and the tank was refilled with fuel today. I would recommend anyone experiencing a Fuel Tank Leak give Darren at Triton Liners a call (848-240-0036) Darren@Tritonliners.com to get an out-of-the-box repair option. They travel all over the country. See attached pics.
 

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I found it really interesting to see the work from Triton liners.
A bit over 3 years ago I replaced my fuel tanks. Before doing the project, I did a lot of searching re various repair solutions. I believe I spoke with Triton back then, and for a while they were on my short list.
The reasons I skipped them had nothing to do with work quality. The issue for me was was that they're east coast based and I'm in Calif. A west coast job meant them driving two rigs cross country (I believe one had a CNC plasma cutter they used to make tank panels on site). Alas, the 2 way travel & time charges and I think there were also manpower lodging costs for the job duration, meant the total price point them out of the running for me. Viable for a larger boat/job but not cost competitive for me. Your pics sure do show some nice work by them!

I really enjoyed seeing your post & pics.
 
I had a huge advantage: the boatyard where the work was done was 5 miles from the Triton owner's home, so he could sleep in his own bed at night. I used the Seminole Boatyard in Jupiter, FL. He still had to fly in two of his guys and food and lodging for them, but the trailer with the machining and welding equipment was local.
 
When I was a young pup, I used to crawl into cryogenic tanks, cut baffles out and weld new ones in place. I'm a small guy so I was the go-to for crawling in those spaces. This was prior to the confined space permits and such. We had an air hose, paper mask, leathers, and it was one of the worst jobs ever. I only lasted three long summer months before I was looking for other work. But these kind of repairs really slams home the importance of maintaining your fuel. Keep water out, polish those tanks as normal operation, not maintenance.
 
I'm curious about the heat of the weld affecting whatever is adjacent to it. Did they take precautions to prevent damage to fiberglass or whatever supports the bottom of the tank where they were welding.
 
Did you ever ascertain the reason/location(s) of the original leak? I'd be hesitant to just replace one tank with another without knowing the reason for the original failure . . .
From you pics, the original tank looks to be almost pristine in condition. If it was a matter of pinholes/porosity of the welds, or some such, i would think that an application of an aviation style fuel tank sealant/liner might have been more appropriate.
I assume you already looked in that type of fix, but would like to hear your reasoning, and especially the reason the original tank began leaking.
Best of luck with your repair!
 
The boat is a 2007. The centerline tank sits low with only about 1 to 1 1/2" of clearance from bottom of the bilge. The tank liner company identified external corrosion on the bottom of the tank, (they said it was the worst they had ever seen). The only reason I can think of is that the tank was frequently wetted with bilge water, possibly leading to increased electrolysis, which created a corrosive environment. I verified the tank is bonded appropriately. The repair is complete, and I have since installed a dry bilge system to keep it dry. I suspect the tank has had a small leak for a few years (My wife always complained about the diesel smell). After returning to Florida this Fall I noticed measurable diesel in the bilge, and I knew it was time to do something. This repair comes with a 5-year guarantee. The two saddle tanks are above the centerline tank and gravity flow down into this tank. They are well protected from still water.
 

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Hi this is Reality in Florida & we also have a 2007 43 Pilot.
Thanks for sharing your fix.
 
Thanks for the reply. I figured for such a major job you would have considered the options before choosing.

One note is that on the jobs I have seen (mostly on Grand Banks), the overall fuel capacity wasn't reduced because they go in with stacked tanks (this is all pre-designed so they fit together well).

So they cut out the big original tank and pull it out in small pieces. This is a loud job but doesn't seem to take very long, really. The new tanks are of a size that they can be put in (or pulled out in future) through the existing spaces; they are stacked and interconnected so they act as one tank, and then on you go.

You might lose a few gallons of capacity but essentially they end up the same size. You don't know they are smaller, interconnected tanks in actual usage.

I never knew about the method of building a tank-within-a-tank that you show. Very interesting.
Hi Frosty, what is the name of this company? Thanks.
 
Hi Frosty, what is the name of this company? Thanks.
It's this one, American Tanks. IIRC the proprieter's name was Vince plus son Brian. I was reading about their Grand Banks re-tankage projects - for some they were traveling to east coast or other locales (they are based near San Diego).


I have not used them, but was seriously considering buying a Grand Banks at one point, so wanted to know what I'd be in for if replacing tanks. Hence reading threads, etc.

Looked like what they typically do is cut up and remove the old tanks, then go in with smaller/stacked tanks that can slip into place around everything in the engine room, and that still perform as "one tank" (one port, one stbd), with relatively little loss of capacity.

I had also read this article by Oxford Yacht on the Chesapeake. They outline something similar.

 
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Wondering if anyone has tried fuel tank slosh sealant. Years ago I had luck with sealing a motorcycle fuel tank. Maybe applicable to leaks at the bottom of the tank. The hardest part would be sloshing it around and then getting the excess out. At the time I heard it was used on new aircraft fuel tanks as part of the manufacturing process, so if it works it should be more than temporary.
 
I went through replacing both tanks on our Mainship 400 last spring (there are a couple of threads about it for those of you who care to look.)

It's interesting to compare the pros and cons of replacing the tanks vs having a professional repair done by someone like Triton. Both options have merits and neither is easy or cheap.

I called and spoke with Triton and found them to be professional and of high integrity. He told me they could do my tanks, but that it would be expensive, along the lines of what E-Sea paid, except I needed both tanks done, so almost twice as much.

The cost to work with Triton was just too high for me, though I think they do great work. In the end he advised me, given my situation and ability to do a lot of the work myself, to replace my tanks and not use their services.

I ended up cutting my main salon floor for access and replacing both tanks. It was a BIG job that required removal of both motors, batteries, exhaust hoses etc. I pulled the port tank intact, but cut up the stb tank to get it out. The new port tank is the exact same size as the original, but I lost 20 out of 150 gallons on the starboard side. I did the port side first, before I knew as much about the best way to do the job. If I had to do this job again (God forbid) I'd cut both tanks up to get them out and install the slightly smaller tanks on both sides.

I did most of the labor myself, with help from the yard where needed. That saved me a LOT of money, though it was month's worth of hard labor. I also used my mechanic to prep the motors for pulling and to re-install and align them after they were back in.

All in, I spent $12,500 for both tanks and everything associated with the job except the cost of the new Lifepo house bank.

Some notes:

There are some big not so obvious advantages to pulling the tanks and replacing them with new tanks.
I installed sight gauges on the new tanks.
I now have new tanks, built and installed better than the original Mainship tanks (see note below). I used TNT in Fort Pierce, they did a great job and my new tanks are beautiful.
With both motors out I was able to clean and paint the entire engine room (turned out great).
I was able to improve wiring issues due to easier access.
With the motors sitting in the yard, I gave them an extensive strip/degrease/repaint job, replaced hoses etc.
I replaced my motor mounts on one side (other didn't need them).

Mainship tanks are thinner than the industry standard and at least in my case, poorly installed. They sit too close to the deck which causes corrosion. In my now educated opinion, virtually all 2000s era Mainship owners are going to face tank leaks in the next five years or so, if they haven't faced them already.

There are some disadvantages too.
It was a lot of work. If you can't do some of the labor yourself it may be similar price to have a company like Triton repair the tanks.
My floor is cut. It doesn't look bad, most of the seam is under the couch, but you can see it. At some point I may repalce my synthetic teak flooring to cover it, but I'm good with it now. I reinforced the floor, so sagging is not an issue.
If you do a tank replacement the job is more of a worm can, one thing leads to another and you end up doing most of a refit in your ER.

Anyway, OP, I'm glad your tanks turned out well. The pics look great.

Doug
 
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