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Old 19-05-2021, 12:10   #1
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Location: Plymouth UK
Boat: Bavaria 37c 2006 model
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Tayana 42 fuel tank

Calling all Tayana 42 owners of experience...
What is the cost of removing and replacing the black iron fuel tanks on the Tayana 42 please . Who did you have the work done by? When did you have it done? Is the problem better or worse for the centre cockpit version?
Thanks Simon
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Old 19-05-2021, 17:26   #2
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Location: Long Beach, CA
Boat: Tayana Vancouver 42
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Tayana 42 fuel tank


Wannabe, I see in your profile you have a Bavaria 37. Are you asking for a friend or buying a Tayana? Iíve posted about my tank solution before but Iíll try again here. Other people have used various mending putties inside fuel tanks which I did not try. Some have cut the old tank into pieces to get it out and put several smaller tanks in place. I opted to insert a bladder into the old tank.

Like many boats the tanks in a Tayana 42 are installed before the interior is built in place. That makes getting a leaking tank out and a replacement tank in very difficult and requires substantial demolition of the beautiful interior woodwork. I decided to go the route of inserting a high quality bladder inside the existing black iron tank.

I did this after one of my black iron diesel tanks developed a pin hole leak in the lower outboard welded seam of the tank. Fortunately, it was the starboard tank which is under the galley but has some access panels in the sole above the forward part of the tank. On the port side there arenít any access panels in the sole above the tank except at its forward end by the nav table.

In addition to opening up the top of the tank you have to remove any baffles in the tank and grind them down smooth so as not to have any chafe on the bladder. I also padded the inside of the iron tank with rubber decking tiles before inserting the bladder. You want a high quality bladder tank builder to manufacture one to the exact dimensions of the inside of your existing tank so you need to measure the rhomboid shaped tank very carefully.

I used Aero Tec Laboratories, Inc.
Spear Road
Ramsey, New Jersey 07440
201-825-1400
ATL@ATLINC.COM

Cost was $1296 in 2004. That was in addition to the cost of grinding out the baffles in the iron tank and installing the bladder.

Since 2004 Iíve had zero problems with the bladder inside the old tank.
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Old 20-05-2021, 11:04   #3
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Re: Tayana 42 fuel tank

I am considering buying a Tayana 42. Thanks for your reply. Seems a good option. Was this only the starboard tank you tackled? How many hours in involved in cutting and grinding the tank? Did you do this? Do you have any issues without the baffles? What about your port tank?
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Old 21-05-2021, 08:38   #4
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Re: Tayana 42 fuel tank

Only my starboard tank had a leak, so I have not needed to tackle the port tank.

The person I hired to cut, grind and measure the iron tank was a plumber who had just finished a years long project building the systems on a sail training ship in Los Angeles harbor. He put in a good week of full days in the uncomfortable work of cutting open a large enough portion of the top of the tank, laying with his head down inside of the tank with a grinder cutting out the baffles and grinding the remains smooth. Then more time upside down measuring the exact dimensions of the inside of the tank. After completing my job he moved to New Jersey to take a regular, steady plumbing job away from boats.

The bladder tank is stuffed with a mesh material from the same manufacture instead of baffles. (It looks like a loofah sponge.) It is the same material they use in aircraft fuel tanks to prevent sloshing and it works fine in my boat. It does displace a small percentage of space in the tank so my old 65 gallon tank now holds a bit under 60 gallons.

I hope it will not become necessary but if it is ever required I would not hesitate to use the same approach on the port tank. It may require some cutting of the sole in the quarter berth to gain access to the top of the tank which will add a small amount of carpentry to the equation.
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