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Old 26-11-2011, 12:42   #1
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Odd-sized Deck Fill

The inside threads of the fuel deck-fill (aluminum) on my boat has corroded, such that the fill cap is almost impossible to take off. After a bit of effort I managed to take out the deck-fill, assuming that it's a standard size and can be easily replaced. To my surprise, it has OD of 1-3/4" (i.e for a fuel hose of 1-3/4" ID). It seems 1.5" is the standard and I have not been able to find a 1-3/4" at all. Any suggestions? I am thinking buying a standard size deck-fill and then wield a 1-3/4" pipe to make it fit with the existing hose, but putting a barb on the extension pipe may be difficult.


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Old 26-11-2011, 12:59   #2
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Re: odd size deck fill

I have an old alum. diesel deck fill that I plan to replace soon. It has a little paint on it here in the picture, it seals good and in fairly good condition, but obviously old.
If interested, I'll check its sizes and get back with you.

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Old 26-11-2011, 13:03   #3
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Re: odd size deck fill

Just get a deck plate with female pipe threads and adapt as needed. It should be fairly straight forward. If the fuel fill hose is older I would inspect it for cracks and dry rot. You might need to replace that as well. Of course 1-3/4" is an odd size for fuel hose so you might need to change the size of that and of course the fitting on the tank would then be the wrong size. God I love working on boats! It is a never ending adventure!
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Old 26-11-2011, 14:12   #4
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Re: odd size deck fill

Seems to me that updating the deck fill and fill hose to meet current standards would be the best long-run solution. A reducing adapter to connect the new hose to a short piece of 1.75" to fit the fuel tank fitting is all that would be needed to allow the fill and hose to be replaced with the current 1.5" standard size.

Fwiw, the average lifespan of any hose is about 10 years...after that they become hard and brittle and prone to cracking. So if yours are old than that, they should be replaced anyway.
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Old 27-11-2011, 00:08   #5
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Re: odd size deck fill

Thank you all for your helpful suggestions. Sounds like replacing both the hose and the deck fill to standard size is the best solution. Now I need to see if I can get the 1.5" hose and an adapter to the tank. Not that straight forward as I am in Barcelona, Spain. The search continues...

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