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  Topic Review (Newest First)
03-19-2014 04:00 PM
Re: Seafarer 38 fuel tank replacement

The tank is out, what a job, tank resisted all the way, out broke two come- along handles in the process. Here's what I found. The tank was made of stainless steel and was in excellent condition, two baffles located equidistant from ends (about 20" apart) the tank was not fastened to the water-tank in any but relied on the tight fit to keep it from moving up+ down or side to side. They added extra layers of fiberglass to the aft end of the water-tank to keep it from sliding fore and aft. That extra glass was the cause of all the effort as it made the opening smaller than the tank, and this was not apparent until the tank was removed, this caused the tank to compress as it was winched aft. Only by cutting the rear end cap off, cutting the bottom allowing tank to compress was I able to move tank with come-along and then only a few inches at a time. the tank did have 37 years of sludge in it but no rust on inside and was very well made.The reason I was worried about the tank was that I thought it was a steel tank, it was painted and showed signs of rust on the bottom end cap. I don't know if fuel polishing would wave solved the sludge problem but I'm glad I didn't cut the cabin sole. Stay tuned for new tank installation.
03-13-2014 10:32 AM
Re: Seafarer 38 fuel tank replacement

progress report 1977 seafarer 38c fuel tank replacement, 1st built a gantry (2x6) to lift engine and transmission, remove engine (4-108), place engine on dolly, disassemble gantry, roll engine out of way to starboard, drill hole in rear of tank (attachment point for come-along) other end attached through shaft tube use blocking to protect shaft tube, winch tank aft ( enlarge hole in engine compartment bulkhead as needed) it took a little more force than anticipated but it broke free, winched aft as far as front engine mounts would allow (about 14") demolished tank as far forward as first baffle using hand grinder, plan to finish removing tank this sunday weather permitting.
11-20-2013 08:08 PM
Re: Seafarer 38 fuel tank replacement

I think that is the way I would do it as well. Go in through the engine bay and cut as needed. The fuel tank goes a long ways forward. Ours is about 55 gallons and not the 70 or so speced. Best of luck!

I imagine you will end up demo'ing the tank in place. I have no idea how the water tank is attached.
11-20-2013 07:45 PM
Re: Seafarer 38 fuel tank replacement

i am preparing to remove my fuel tank on my 1977 38C. My preferred approach would be to remove engine, and pull the fuel tank aft through the bulk head and out. I don't know how the fuel tank is fastened to the water tank. I do not wish to cut the cabin sole, but would be willing to cut some hand holes in order to gain access. I plan to install a new fuel tank, so I don't care about damaging the old one. If I am unable to remove fuel tank in one piece, my second option would be to demolish the fuel tank in place. Is there anyone that can tell me how the fuel tank is fastened to the water tank? thank you
04-22-2012 12:05 PM
Re: Seafarer 38 fuel tank replacement

Well the tank is out and drained and am now considering materials for glassing found a local sand blast guy who will do job for $100.need to find the best mathod for layup on corners and body.Allso installed new shaft.cutless.andPSS seal today.had to cut shaft tube and claen up sloppy glass work.all went well...will post more woul like to post pics whene I figure out how...
04-14-2012 08:23 AM
Re: Seafarer 38 fuel tank replacement

Sounds like my first plan plastic is great...but i do need the 79 gal cap.because i heat the boat and hot water with the diesel fuel and burn 10>15 gal a week in winter.
04-12-2012 03:10 PM
Re: Seafarer 38 fuel tank replacement

Interesting. Because of the uncertainties involved with cutting out that much floor and the dinette. I decided to gut the tank by cutting off the end closest to the engine and then crawling inside to remove the baffles. Trying to pull the tank out didn't work so I assume it is somehow attached to the water tank. Perhaps epoxied together, pins, i don't know. I have a pair of poly tanks I'm going to put up inside the skeleton of the old tank. Combined its only 34 gallons, but I really prefer the plastic.
04-11-2012 11:37 PM
Re: Seafarer 38 fuel tank replacement

Sorry about the delay still investigating .oh well it would seem the tank measures 60"lx19"w at top 14" wide at bottom and 18" tall.the tank lays inside the fiberglass water tank on 3 sides about 1" below cabin sole and 6" beyond edge of dinnete so the only way out is to cut cabin sole and part of dinnete .after consid.other options i have decided to cut tank out.and sand blast outside and apply a heavy layup of epoxy cloth and west sys epoxy saving the est cost of 900.oo for a new tank.the tank will be easy part putting the boat back together will be not so easy! Balsa cored sole and ireg shapes for dinete.any one have exp. With such a project i am gratefull for any input. Allso have engine out am installing rebuilt 4.108
and new shaft cutless bear pss shaft seal.
03-31-2012 07:18 PM
Re: Seafarer 38 fuel tank replacement


I am attempting to replace the fuel tank on my '76 Seafarer 38C as well. If you find anything out please let me know.


Jon Pry
03-27-2012 09:11 PM
Re: Seafarer 38 fuel tank replacement

Mike, wish I could help you with this but my Seafarer is a 29'. I removed my metal fuel tanks when I purchased the boat 12 years ago and replaced them with polyethylene tanks. Since my tanks are housed in a lazarette hatch separated from the cabin with a bulkhead and with independent ventilation I felt these low-permeation tanks would suffice.

Not sure where the tanks on the S38 are housed, but you most likely will have to go with permanent below-deck tanks as found on pages 604 & 605 of the West Marine catalog.

West Marine eCatalogs

A fellow Seafarer owner, Elan and Ashley are full time cruising on their restored S38C, s/v Silver Lining. They are currently in La Paz, Mexico and will soon be heading down to Panama.

I suggest that you try to get a message to Elan through his blog Sailing Silver Lining

Another couple options for advise is the Seafarer Research Center at Seafarer Research Center

Last on Facebook is the Seafarer Yacht Group. You will find a link to this group on the Seafarer Research Center's home page.

By far the Facebook group is the most active, but the Sailnet forum and the Seafarer Research Group are the primary web sources for networking about the Seafarers. There is also modest interest/activity at Sailboat at this address.
Seafarer -

Good luck!
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