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  #11  
Old 02-16-2009
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Fill the tank with water and you can saw all you want. Fill it to the brim and float all the remaining diesel out the top.
Leave it full, and you will be able to saw the top off.
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I have already cleaned out the puddle with my Jabsco pump. There's only a coating of fuel in the tank. I'll call my diesel guy for advice.

Haven't decided on what tank to replace with. Its an odd shape, so I doubt I'll find anything like it, so I'll have to take whatever fits. That is, unless I have one custom made. Hmmm.

I've seen the plastic Moeller types that come in odd shapes and sizes, so I may go with one of those.

This is one of my main winter projects. The other is to replace my head...
ugh!
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Old 02-16-2009
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My dad taught me a lesson when I was real young. He took an empty metal coffee and put about a cup of diesel in it, he then proceeded to throw lit match, after lit match to show me that it was a very safe fuel that would not light easily, even when spilled. He then proceeded to show me how good it worked with GASOLINE! Good old dad! I still havn't forgotten that one. Since you have your tank out already, how about going to your local rent it store, and renting a hand held metal shear. You can zip that tank into small pieces alot faster and cleaner than a sawzall. Just start at your sending unit hole, and let er rip! No sparks etc., just in case your nerves wont let you pull the trigger on the sawzall.
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If you are worried put some dry ice in the tank. The CO2 will fill the tank and sparks will be no problem.
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You should put a new alu tank in, you can get one custom made for around $500 or so, it will be the right solution. Use the old one as a pattern, reduce the size of necessary to get a tank that you can slide back in place of the original. You won't be able to sell the boat if you put a plastic tank in it...perhaps you could give it away.
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Old 02-17-2009
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I saw this ad in a magazine last night for fuel tanks. I do not know anything about the company but there web site is SpeedyTanks.com: ACW Marine Fuel Tank Fabrication Experts Perhaps talking to them before cutting the tank might offer some more insight on your project. Another thought would be to take some good measurements of the existing tank before you cut the tank, good enough that you can draw the all three dimensions on a piece of paper. It might be easier for reinstalling and securing using a similar design.

We replaced our head hoses last year. They were easy to remove but difficult to reinstall. I warmed the hoses on my dashboard of the van then installed, it seemed easier to work them when warm. Laying them in the sun also helped.
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All petroleum products should be accepted as explosive. The best method is to use the exhaust gases of a running engine. Use a proper diameter metal tube (or rubber if the gases are already cooled down) to transfer exhaust gases to the inlet of tank. You can even weld the tank under this conditon.
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