FINALLY got the fuel tank access port job done and the tank is back in the boat. Took me three months of (intermittent) work and turned into a bit of a nightmare. The main issue was the top of the tank was very wavy and not at all flat, so I had to make a very robust access port in the style of the Seabuilt system. However, with so many bolts this turned into a big struggle to get them all to fit properly. When I finally got them on and pressure tested the tank the ports held pressure but the fuel gauge did not despite a new gasket.
Tightening the fuel gauge bolts stripped the threads in the tank so I had to manufacture a ring to go on the inside and oversize the bolts and then the bolts wouldn’t tighten from the top since they didn’t fit next to the dial gauge and on and on and on etc., etc, BS. Anyway, it’s done and yes the bolts will protrude a bit above the surface of the cover so I will be using a tick stick to transfer their locations to the cover to cut relief holes.
Long story short it turned into one of my typical boat projects, 3x longer (12x maybe?), 3x more expensive and 3x more complicated than originally envisioned. I’m envious of those of you who were able to do this in a weekend!
