Guest viewing is limited
- You have a limited number of page views remaining
- 0 guest views remaining
- Register now to remove this limitation
Fuel tank replacement cost?
- Thread starter Hilary
- Start date
Prairie Schooner
Jeff & Donna, E35-3 purchased 7/21
We're in RI and had a new 40 gallon aluminum tank made. In addition to the standard fitting mounts, it had two access ports. It cost $1500.
Perhaps the original EY vendor can give you a quote.
ericsonyachts.org
Fuels, Propane & Other - OEM and custom Diesel Fuel Tanks
Berry Marine Tanks in Costa Mesa CA made many of the original tanks in our Ericsons. Vic still has many of the original plans for the tanks, although I just took my old tank to him and he duplicated it beautifully. Superior welding skills, IMHO. Fair price. I'm not sure if he will ship, though...
K2MSmith
Sustaining Member
Berry’s tanks charged my 1K for an 1/8” thick 40 gal aluminum tank which was cloned from original. He also has original drawings from Ericson . That included new sensor , fittings , inspection port and ground tab . I spent probably another 100-200 on extraction pump , hose clamps , filler line, fuel cans etc. I received a ball park quote of 4-5K to replace it at the yard . Was my time worth saving 3K ? I’m not sure . I’m still not done .. lol .
Brad Johnson
Member III
I had one made for my 1988 E26 and it was $675
PANorth
Member II
We just went through the experience of dealing with a leaky tank. Removing it would have required dismantling the cabin in part or in whole. We didn't want to do that so, on advice of someone in another thread on this topic, we painted expoxy inside the tank. Our first effort consisted of just painting the lowest part of the tank, on the assumption that the leak would be there. It still leaked. We emptied it again and thoroughly cleaned it out. We used Simple Green as the soap, followed by copious rinses with a garden pressure sprayer. Then we painted the lower third all around. It required that we cut another port in the top and have a cover made to close it up again. It has only been two weeks since we filled the tank again. So far so good.
I just replaced my tank in my E32-3. Coastline Equipment in Bellingham, WA made a replica from measurements I took of the old tank. Very high quality with an extreme attention to detail on measurements and fit. The new thank has a beefy inspection port, a new fuel gauge sender, and NPT hardware for vent and supply. I couldn't be happier. Cost: $1300 + $250 shipping
I also spent about $500 in parts to replace all hoses, connections, clamps, etc.
I also spent about $500 in parts to replace all hoses, connections, clamps, etc.
Rather than start a new thread, I'm going to add to this:
My (E350, basically E34-2) tank is leaking; looks like from a small spot/area at a weld on the forward lower edge. It did leak 1.5 L in 4 hours (mostly sailing), but is down to maybe 0.5 pints/day at the dock... I suspect weld opens farther when boat flexes.
Anyway, someone on the (vast number of) threads on leaking fuel tanks here said they are typically good for 20 years, so I'm going to a new one.
Getting an aluminum tank.
--> Is there any reason to get 3/16", or is 1/8" fine?
--> How about aluminum grade (5052? Or something else?)
@vanilladuck -- after two years, how are you feeling about Coastline's tank?
@K2MSmith -- how is your Berry tank? Did you find source of the leak, and was it your new tank? Do you still recommend them?
@Loren Beach -- Somewhere you mention a Wema gauge sensor... could you expand on that?
And the hard one... does anyone else with a Pacific Seacraft - built Ericson (mine is an E350) know if the tanks are exactly the same as an E34-2?
Any other advice welcome. This is not the way I had hoped to spend the summer sailing season...
My (E350, basically E34-2) tank is leaking; looks like from a small spot/area at a weld on the forward lower edge. It did leak 1.5 L in 4 hours (mostly sailing), but is down to maybe 0.5 pints/day at the dock... I suspect weld opens farther when boat flexes.
Anyway, someone on the (vast number of) threads on leaking fuel tanks here said they are typically good for 20 years, so I'm going to a new one.
Getting an aluminum tank.
--> Is there any reason to get 3/16", or is 1/8" fine?
--> How about aluminum grade (5052? Or something else?)
@vanilladuck -- after two years, how are you feeling about Coastline's tank?
@K2MSmith -- how is your Berry tank? Did you find source of the leak, and was it your new tank? Do you still recommend them?
@Loren Beach -- Somewhere you mention a Wema gauge sensor... could you expand on that?
And the hard one... does anyone else with a Pacific Seacraft - built Ericson (mine is an E350) know if the tanks are exactly the same as an E34-2?
Any other advice welcome. This is not the way I had hoped to spend the summer sailing season...
frick
Sustaining Member
I took my old E29 15 Gallon tank toa local shop on Long Island. They replicated the tank perfectly. This was 20 years ago, but it was a sub 300 dollar fix. It was cheaper than buys a plastic tank from West Marine which would have required all new hoses as the old ones would not match up.
Also, When I pulled in the A4 in 2002, I had all the hoses replaced for Diesel. It just made sense to have the duplicate tank made.
Also, When I pulled in the A4 in 2002, I had all the hoses replaced for Diesel. It just made sense to have the duplicate tank made.
I discussed our new tank in this thread: https://ericsonyachts.org/ie/threads/diesel-tank-replacement.6303/
Our Wema gauge and sensor is still working fine. In the decades since, I did have to have one pin-hole leak patched when a drop of water sat on one place on a seam a long time (a surmise by me and the expert welder).
I am glad I opted for the slight increase in thickness, over the OEM tank, which seemed kinda flexible-ish to me. On that point I believe some added wall stiffness/ strength is good for getting a long term seal for access ports and other fittings, also
I would still recommend getting a quote from Coastline, up in Bellingham. Quality work, they did.
I still love being able to energize the "instrument" circuit and have the tank level gauge I installed at the nav table inform me.
Our Wema gauge and sensor is still working fine. In the decades since, I did have to have one pin-hole leak patched when a drop of water sat on one place on a seam a long time (a surmise by me and the expert welder).
I am glad I opted for the slight increase in thickness, over the OEM tank, which seemed kinda flexible-ish to me. On that point I believe some added wall stiffness/ strength is good for getting a long term seal for access ports and other fittings, also
I would still recommend getting a quote from Coastline, up in Bellingham. Quality work, they did.
I still love being able to energize the "instrument" circuit and have the tank level gauge I installed at the nav table inform me.
Last edited:
The tank Coastline Equipment made for me is 1/8" 5052-H32 aluminum and included the fuel sender, vent tube, fill tube, and draw tube. It also has a beefy cleanout port that's about 8-10" in diameter. Jayson was very communicative and easy to work with. I've had zero problems with the tank. I'll be the first to mention I haven't sailed my boat a ton since installing the tank in Dec 2023. The rig came down (on purpose) from April 2024-2025 for a massive overhaul. Rumour has been out for day sails and local cruises around the bay, but no big ocean sailing or coastal cruising yet.
One note on installation: I glued 1/4" thick strips of heavy neoprene rubber from McMaster-Carr to the underside and corners of the tank with 5200. This will hopefully keep the tank from rubbing on the unfinished fiberglass in the fuel bay in the port quarterberth of the E32-3. I also zip-tied strips of the rubber under the retaining bars to hold the tank in place. Jayson and I agreed that making the tank a wee bit smaller than the old tank was wise to ensure it fit in the boat.
Prairie Schooner
Jeff & Donna, E35-3 purchased 7/21
That's a pretty significant leak.
Good advice from Bryan. I felt most comfortable taking our old tank in so it could be replicated exactly, if you can find a local fabricator. I wish I had been more specific with our fabricator, questioned more. He installed two access ports as I asked, but they are smaller than I'd like. I can barely get a hand in.
It's likely in your research you've seen how some people have rigged a fuel jug as a temporary fuel tank. If it's going to take a while to get your new tank made, that would be an option to keep your boat in play. As long as it doesn't seem too sketchy to you. Personally, I'd be okay with it for a few months. - Or, others have repaired tanks with fiberglass. That might get you through the season.
K2MSmith
Sustaining Member
Hi--
I had a new tank made at Berry's shop in Costa Mesa. I drove the old one down form the Bay Area and he made me a new one in a few weeks with upgraded 1/8" aluminum. I chose not to take the new tank out again to investigate the leak, so I cleaned it up the small amount in the bilge and watched it for a few months and never saw any fuel again. My theory is that is was residual fuel somewhere that ran down in to the bildge because I checked all the lines. Another theory is that I have a leak somewhere in the filler hose near the deck, I poured the saved fuel into the deck filler but with a short funnel, so perhaps some fuel could have ran down from the deck fitting (?). At any rate, that particular project combined with a very bad experience with a rigger having my standing rigging replaced left me a bit burned out on boat work so I have taken a break from it from a while and have just gone sailing...
E32-3 - A Temporary Janky Tanky
SV Rumour had a leak in her diesel tank. Not surprising after 3/16" aluminum sat on and rubbed and vibrated against the raw fiberglass hull for about 38 years. You'll find quite a few threads in the forums here with folks finding pinhole leaks in...
It's now been passed on to a slip neighbor with an Ericson 35 who is using it to test his new diesel engine before he swaps out his Atomic 4
Many thanks, all! It's depressing to have this happen right as I have time to sail... really nice to have people who can help me sort it out efficiently -- deeply appreciated.
- Sounds like everyone's going with 1/8"... anyone sizing up to 3/16", I'd be interested to hear about it. Loren: if you did it again, would you go up from 1/8" ?
- Vanilladuck: Did Coastline put in the brass fittings and label everything (in your image above), or did they provide the tank and you had to get all the fittings? Trying to figure out if this will be plug-and-play.
- Prairie Schooner: what diameter are your inspection ports? Want to size up based on your comment. I see VanillaDuck has 8 or 10" ones.
I'll see if I can find someone local, but suspect I'll end up driving my old tank to someone to copy. And Coastline/Bellingham is (much) farther than Berry/Costa Mesa... though I'll definitely talk with both.
Yes, a pretty large leak... which was very sudden: Bilge dry in the AM, then after a 3-hr, not-too-boisterous sail suddenly a bunch of diesel. Which did not look pink in the bilge, only after getting some on a paper towel; must have to do with the light transiting twice on reflection from the bilge (or, I guess, maybe that the bottom of my bilge is not and never will get as clean and white as one of the image Christian posted of his somewhere.)
- Sounds like everyone's going with 1/8"... anyone sizing up to 3/16", I'd be interested to hear about it. Loren: if you did it again, would you go up from 1/8" ?
- Vanilladuck: Did Coastline put in the brass fittings and label everything (in your image above), or did they provide the tank and you had to get all the fittings? Trying to figure out if this will be plug-and-play.
- Prairie Schooner: what diameter are your inspection ports? Want to size up based on your comment. I see VanillaDuck has 8 or 10" ones.
I'll see if I can find someone local, but suspect I'll end up driving my old tank to someone to copy. And Coastline/Bellingham is (much) farther than Berry/Costa Mesa... though I'll definitely talk with both.
Yes, a pretty large leak... which was very sudden: Bilge dry in the AM, then after a 3-hr, not-too-boisterous sail suddenly a bunch of diesel. Which did not look pink in the bilge, only after getting some on a paper towel; must have to do with the light transiting twice on reflection from the bilge (or, I guess, maybe that the bottom of my bilge is not and never will get as clean and white as one of the image Christian posted of his somewhere.)
I would keep it the same as built. Coastline may have (?) my old build order in their files for a reference. (On a hard drive somewhere...)
PANorth
Member II
Here is a response of the different nature - We asked on this same forum when the tank on our 1982 E38 started to leak. We seemed to be faced with tearing apart cabinetry to replace our tank. Instead I followed the advice of a minority opinion and tried sealing the tank with epoxy. I cut as second hole in the top so that I could reach the whole inside of the tank. I thoroughly scrubbed out the tank, then coated the lower half with a couple of coats of epoxy. I had to make a cover for the new hole. That was no problem at a local metal manufacturing shop. It has been two years with no leaks.