I need to remove the 140 gallon fuel tank from my boat. I need to cut a notch in the top of the tank to be able to get it out. It has been emptied, but did contain gas. Can someone suggest a safe way to cut the tank?

 

Hey Scottman, glad to hear from ya. Just pull the cap for a few hours or days to let any vapors dissipate and it should be fine as long as it's dry. Worst case scenario even if there is some drops of fuel in the bottom of the tank it would just burn away. As long as its not sealed no worries about explosions.

Depending on how wide and long the cut is you can use about anything to cut it. A body grinder, hacksaw, sawzall, just about anything you have handy will go through alluminum.

The real trick will be gettin a good welder to stitch it back up right.

 

Hey, Dennis, good to hear from you.

I am replacing the tank, so it doesn't matter what condition it gets in. I've been given nothing but horror stories about cutting it and am now a bit scared to cut into it. Are you sure it's safe? I was told aluminum doesn't spark when it's cut, is this true?

 

I've never had Al spark on me.
blow compressed in the pick up tube it'll vent out of another hole.

 

If you use a body grinder it will spark, but not if you use a saw. The metal is to soft. An explosion can only happen if it is a sealed container otherwise it just throws a fireball and burns itself out even if there is still fuel residue in there. I've burned through a fuel tank full a fuel using a torch to cut stuff off the frame and got careless and the only thing that caught fire was what spilled out. I had to stick my finger in the hole and hollar for somebody to bring a tank over to drain the fuel into.

But to answer your question, as long as all the fuel is out and it has aired out for a while your fine. If you really wanna test this just drop a match in an old fuel can that has sat around with the cap off.

Be sure to let us know if I'm right.

 

I'll have my wife drop you a PM if I don't ...

 

I gotta ask though. Why are you pulling this tank. Theres really nothin that can go wrong with an alluminum tank is there.

 

When the tank was installed, 27-28 years ago, it was bedded in foam. Unfortunately, moisture gets between the foam and the tank and corrosion begins. Since I am repowering, I am pulling the tank and replacing it. So far, it appears that the tank really didn't need replaced. Sort of like a KDP on a 24 valve, you don't know what you've got until you pull it ... isn't that right Doctor!

 

yep...

and sometimes a sloppy build will have a screw under the tank that will abrade a hole in it.

 

There has never been a sloppy built Skipjack! One of the best built boats on the left coast ... but their tanks have been a weak spot.