Whaler Central - Boston Whaler Boat Information and Photos

Posted by Clay Fischer on 08/12/08 - 5:46 PM

I have to replace the fuel tanks in my 1985 25' Frontier. There are two 70 gallon tanks in the boat at present. I believe Whaler went to a single tank a few years later and want to replace the two tanks with one.

I have pulled the deck to get access but am at a loss at how to extract the tanks with the blown in foam all around.

Any suggestions and input will be much appreciated.

Posted by Phil T on 08/13/08 - 5:20 AM

Clay -

Welcome to Whaler Central.

Jeff did a comprehensive repair of his tank cover and removed some of the foam.

If you scroll down to photo #44, you can see the tool that many use. Scraper on a broom handle.

Jeff's Article

Feel free to ask any questions along the way. Many members have done their tanks and can advise you.

Posted by Jeff on 08/13/08 - 7:39 AM

Clay,

Once you remove the foam from around the tanks some have used pry bars or come along hoists to pull the fuel tank lose.

You can get a brand new tank for your boat from Florida Marine Tanks. They were the OEM supplier for whaler and can built what ever tank you want to fit into your boat.

Edited by Jeff on 08/13/08 - 7:39 AM

Posted by timh on 08/13/08 - 6:30 PM

last year when i pulled my fuel tank out, i built a frame made of 4x4s. one on each side of the boat verically, and one spanning the two horizontaly with a come along attached to the horizontal piece i pulled the tank from one of the fittings and it popped right out. sorry no pics i lost them on my computer.

Posted by Binkie on 08/13/08 - 8:51 PM

I removed a built in fuel tank from a 24` Aquasport. I dug out as much foam as possible and wedged an 8 ft. 2/4 between the tank and the cavity wall, and started prying. Once you are able to move it a fraction on an inch, it will pop free. With the price of aluminum the way it is now, it is worth more than you think at the recyclers. Make sure you flush it with fresh water, and remove any unlike metal screws for the best price.

rich

Posted by Clay Fischer on 08/14/08 - 7:12 AM

Thanks for all the input. Now I know I have my work cut out for me. I will use a flooring scraper to remove the foam, it is heavy and narrow, then hoist the tanks out. I think I'll go back with one tank instead of the two it came with. I understand Whaler went to a single tank a few years after the boat was built. Any opinions on that??