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I recently fished 1983 18' Outrage for several consecutive days. Over that period, we experienced heavy rains over night. Awoke the next morning with boat tied to dock and had approximately 1" of rain water in cockpit. I pumped the water out using a hand pump inserted into bilge. I started engines and both ran fine. 5 minutes after leaving the dock, starboard engine started running rough and then stalled and would not re-start. Port engine stalled shortly there after and would not re-start. Brought boat to mechanic who drained tank and discovered water in fuel.

Boat ran fine for three days prior to rain (prior to in-hull tank being covered with rain water) suggesting no water in fuel prior to rain. Fuel fill cap was installed and torqued sufficiently to prevent rain water entry into tank.Additionally there is no smell of fuel in bilge.

Has anyone had similar experience and can you suggest best means to test tank, fill line, vent line, delivery line and fuel gauge to identify point of water entry into fuel system?

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Pull the inspection ports and smell for fuel.

Are the hoses less than 5 years old? If not, replace all (fill, vent, supply) wit h alcohol resistant hoses and double stainless clamps.

Is there are primer bulb in the supply line?

You also need to do a pressure test (2 psI) on the tank.

Run a portable deck tank in the interim and add a fuel/water separator for the time being.

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I have the same boat 1985. I have removed the 5" flat plate that is under the rear deck and replaced the gasket with a gasket I cut out of 60 mil. rubber EPDM. There are about 8 small bolts that hold it in place, and the fuel pick up comes out the top.

I wish Whaler had speced a tank that had a raised lip at that location as any water that gets on the deck is washing over that penetration. In your specific case leaving the drain plug uot would probably eliminated some of the problem. My boat at anchor with the plug out is self bailing except when someone stands in the stern.

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I totally agree with mtown. I had the exact problem with 1989 20’ Outrage. The ethanol fuel destroyed the gasket on the rear inspection plate that holds the fuel pickups on my tank. Made new gaskets. All good. I would use this time to replace all the fuel lines on the tank.

Good luck. Keep us posted.

Stephen

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Thanks to all for your very helpful replies. Fuel tank flange gasket sounds like most likely path of water entry. I recently repowered and replaced fuel fill line, and delivery line hoses. I also have water separator/filters installed. I need to check vent line as I don't know that it was changed. Flange gasket has not been changed and will be my first action.

Can you suggest where I may obtain 60 mil. rubber EPDM?

Also, any further information on best means to apply 2 PSI on tank would be appreciated? Would a large aquarium tank pump work to establish positive pressure on tank with little potential to over pressure?

Again, thanks to all for your very informed replies...Tommy

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Go to a roof center or other good roofing supply store. Ask for a sample of EPDM or TPO.

The sample is just about the size you need. Any commercial roofing contractor will have scraps of it also.

I have also used strips of it to support water and electric lines under my pier. Soft and strong, it does not chafe the plastic pipe or the wire.

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Thanks mtown for sharing source for EDPM.