I am going to help a friend remove and replace the inboard fuel tank in his Key West. This involves removing the console, cutting a hole in the deck, removing the old metal tank, and installing a new plastic one. Then reinstalling everything else. I consider myself to be pretty mechanically savvy, know my way around the electrical systems, and not bad at glass work. I have a workshop with all or most of the tools required, so I know that this is a doable project.
Has anyone done this project before and if so, can you share any hints, tips, tricks with me?
I have to do something similar in my boat soon. Would you mind a helping hand? I’m good everywhere but the fiberglass part and could use some first hand experience.
LMK
Thanks
Joe
Plan is to start at my house tomorrow on James Island at 10 am. We are going to and get the demo done tomorrow. Fuel tank is ordered but will still be a couple of weeks out. I don’t mind if you come by to check it out. If you want to stop by you can. My phone number is 843-327-5735 or email is engineer-diver@hotmail.com
I haven’t done it on a Key West, but have on several others, the most recent being a Grady. It was a big job, had to remove the T-top, cut out and remove the console with all wiring, steering and control cables, cut out the sub floor, dig out all the old foam, pump out the tank and remove it. Rebuild the tank compartment, install and plumb new tank, new foam, build and install new sub-floor, re-install console and top, rewire everything, test everything…It took almost a month working full time!
One more thing that might be useful. I don’t know about KW customer service but it might be worth giving them a call. On the above boat(1987 model) I called Grady White to try to get the specs of the tank and where exactly it was located. They put me on the phone with a tech who knew it inside out, he emailed me the original tank dimensions, entire replacement procedure including pictures of where to cut, how to remove it, how to re-install, everything I need to know in one phone call. Fantastic customer service from GW for a 25 year old boat!
The only thing they could have done better is send someone down to change it for me Even when you know how, it’s not easy.
I cut up a 1989 key west sportsman and the tank was right under the console. It had a cover over it that the console was attached to and there were a lot of screws holding the cover down. There is a WHOLE BUNCH of foam around that thing.
Radius your cutout so that when you glass the deck cap back on you don’t have sharp corners where stress is concentrated and guaranteed cracking later on after your repair.
The boat doesn’t have a caulked down fuel coffin lid that you can unscrew and pull off?
I wish I could have been there but I have reserve duty all weekend.
How did getting it out go for you? I’m on JI too. I wouldn’t mind helping glass it in.
Are you going to make a coffin lid or glass it all the way back in?
I wish I could have been there but I have reserve duty all weekend.
How did getting it out go for you? I’m on JI too. I wouldn’t mind helping glass it in.
Are you going to make a coffin lid or glass it all the way back in?
Even when you know how, it’s not easy.