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09-11-2021, 13:02
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#1
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Registered User
Join Date: Nov 2017
Location: Galesville, MD
Boat: Broadblue 42
Posts: 10
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2005 Broadblue 42 fuel tank repair
We have a leaking fuel tank on our 2005 Broadblue 42, hull 6. The tank is stainless steel, 58 gal. Has anyone had to repair a similar tank? It cannot be removed from the boat in one piece. What are my options? Welding? Applying an adhesive sealant? Cutting it up, removing it, and replacing with a plastic tank that can fit through the 19 inch hatch. Thanks.
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11-11-2021, 03:40
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#2
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Registered User
Join Date: Oct 2010
Location: Gig Harbor, WA
Boat: 34' Crowther tri sold 16' Kayak now
Posts: 5,067
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Re: 2005 Broadblue 42 fuel tank repair
I've had good luck with JB Weld Tankweld. It's an epoxy specially formulated for fuel tanks. I fixed my girlfriends car gas tank and it lasted years, longer than we did.
If you decide to remove it you might want to consider a custom made fuel bladder. This company makes any shape you need and you can probably stuff it down a smaller opening.
http://atlinc.com/marine.html
__________________
Slowly going senile but enjoying the ride.
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11-11-2021, 05:54
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#3
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Moderator Emeritus

Join Date: Feb 2012
Location: Carrabelle, Florida
Boat: Fiberglas shattering 44' steel trawler
Posts: 6,082
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Re: 2005 Broadblue 42 fuel tank repair
Whether you're dealing with pin holes in the welds or in the bottom surface, are they accessible? If they are, take Sand Crab's advice as a first try, squeezing the epoxy in through the holes with a spatula. If that fails, then yes, it's time for surgery.
Unfortunately, you may be playing catch up, because if there are a few holes now, there are other thin places just waiting to break through.
__________________
Never let anything mechanical know that you are in a hurry.
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11-11-2021, 07:08
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#4
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Marine Service Provider
Join Date: Jan 2011
Location: St. Petersburg, FL
Boat: Retired Delivery Capt
Posts: 3,739
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2005 Broadblue 42 fuel tank repair
PLEASE PLEASE PLEASE
Make sure whatever product you use is food grade. What works on a diesel tank is likely NOT food grade
Why is that important? Many products will cause all sorts of maladies if consumed.
__________________
"Whenever...it requires a strong moral principle to prevent me from deliberately stepping into the street, and methodically knocking people's hats off- then, I account it high time to get to sea..." Ishmael
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11-11-2021, 07:38
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#5
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Registered User
Join Date: Oct 2018
Posts: 573
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Re: 2005 Broadblue 42 fuel tank repair
Quote:
Originally Posted by Snore
PLEASE PLEASE PLEASE
Make sure whatever product you use is food grade. What works on a diesel tank is likely NOT food grade
Why is that important? Many products will cause all sorts of maladies if consumed.
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And please do not drink your diesel. Oh, and tide washing machine soap pods too.
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11-11-2021, 07:44
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#6
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Registered User
Join Date: Feb 2008
Location: North Charleston, SC
Boat: Camano Troll
Posts: 5,176
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Re: 2005 Broadblue 42 fuel tank repair
You have little to use trying an epoxy as mentioned above. If it doesn't work, you are only out the cost of the product.
If that doesn't work, talk to a couple good boat yards about repair/replacement. Yes you could cut the tank and remove it, but it may be more practical to cut the boat to remove and replace the tank and then patch the boat.
__________________
Ron
HIGH COTTON
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11-11-2021, 07:57
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#7
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Registered User
Join Date: Jun 2019
Posts: 3,037
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Re: 2005 Broadblue 42 fuel tank repair
Your 58 gallon tank will likely have at least one baffle. I'm not familiar with your boat or the accessibility of the tank. Exterior patches rarely work for long but as others have said, I guess it's worth a try.
If you can get either the top or side, consider installing an access port in each baffled section. You will have to empty the tank, of course, but cleaning the interior extremely well and patching will have a much higher success rate. It's a lousy job, especially working through a small access plate (cough-up the extra dough for larger size).
https://www.fisheriessupply.com/seab...s-plate-system
As far as patch material, I've heard rumor of stuff made for airplane fuel tanks. However, they seem designed to be able to tumble the tank to coat the interior, obviously not an option for an in-situ tank.
Good luck!
Peter
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11-11-2021, 07:57
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#8
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Registered User
Join Date: Nov 2007
Boat: Seawind 1000xl
Posts: 7,462
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Re: 2005 Broadblue 42 fuel tank repair
I like Sand Crabs idea of the bladder. Couldn’t you cut the top of the tank and install a bladder in the remaining 4 sides and bottom of the existing tank?
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11-11-2021, 09:35
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#9
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Marine Service Provider
Join Date: Jan 2011
Location: St. Petersburg, FL
Boat: Retired Delivery Capt
Posts: 3,739
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Re: 2005 Broadblue 42 fuel tank repair
Quote:
Originally Posted by Allied39
And please do not drink your diesel. Oh, and tide washing machine soap pods too. 
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If you are going to be sarcastic—-Please be accurate.
A few fast googles found the JB Weld is NOT FDA approved.
So my dear sir or madam- my post was rather relevant!
__________________
"Whenever...it requires a strong moral principle to prevent me from deliberately stepping into the street, and methodically knocking people's hats off- then, I account it high time to get to sea..." Ishmael
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11-11-2021, 09:47
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#10
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Registered User
Join Date: Oct 2010
Location: Gig Harbor, WA
Boat: 34' Crowther tri sold 16' Kayak now
Posts: 5,067
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Re: 2005 Broadblue 42 fuel tank repair
What does food grade epoxy have to do with a fuel tank repair?
__________________
Slowly going senile but enjoying the ride.
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11-11-2021, 12:31
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#11
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Registered User
Join Date: Dec 2008
Location: SC
Boat: None,build the one shown of glass, had many from 6' to 48'.
Posts: 10,206
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Re: 2005 Broadblue 42 fuel tank repair
Quote:
Originally Posted by Sand crab
What does food grade epoxy have to do with a fuel tank repair? 
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I didn't see the relevance either?
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11-11-2021, 12:39
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#12
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Registered User
Join Date: Sep 2019
Posts: 33
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Re: 2005 Broadblue 42 fuel tank repair
Wake up!
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11-11-2021, 13:12
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#13
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Registered User
Join Date: Oct 2018
Posts: 573
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Re: 2005 Broadblue 42 fuel tank repair
Quote:
Originally Posted by Cadence
I didn't see the relevance either?
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I dont know, unless of course you drink your diesel....please please please don't.
Sheesh, no sense of humor at all snore? Thats got to be a suck of an existence.
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11-11-2021, 13:29
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#14
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Registered User
Join Date: Oct 2018
Posts: 573
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Re: 2005 Broadblue 42 fuel tank repair
Quote:
Originally Posted by Snore
If you are going to be sarcastic—-Please be accurate.
A few fast googles found the JB Weld is NOT FDA approved.
So my dear sir or madam- my post was rather relevant!
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Ok, I'll wade in. Please, dear sir, explain the relevance of FDA approval having anything to do with a diesel tank repair.
I expect you just assumed it was a water tank repair, hey, yeah, you are correct. And have a smile about the mistake, we all make them.
For the OP. No one has mentioned that stainless can be soldered. A permanent fix....depending of course where the hole is, if there are more holes about to appear etc etc etc. But the point is, soldering stainless can be done, do it all the time and might, or might not, be something that will work for you.
The right flux is the trick. Oh, and the old 50/50 lead tin mix is by far the better material. DOH....but that may of course not be good for digestion......
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11-11-2021, 14:51
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#15
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Registered User
Join Date: Dec 2008
Location: SC
Boat: None,build the one shown of glass, had many from 6' to 48'.
Posts: 10,206
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Re: 2005 Broadblue 42 fuel tank repair
Quote:
Originally Posted by Allied39
Ok, I'll wade in. Please, dear sir, explain the relevance of FDA approval having anything to do with a diesel tank repair.
I expect you just assumed it was a water tank repair, hey, yeah, you are correct. And have a smile about the mistake, we all make them.
For the OP. No one has mentioned that stainless can be soldered. A permanent fix....depending of course where the hole is, if there are more holes about to appear etc etc etc. But the point is, soldering stainless can be done, do it all the time and might, or might not, be something that will work for you.
The right flux is the trick. Oh, and the old 50/50 lead tin mix is by far the better material. DOH....but that may of course not be good for digestion......
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I loved the last little bit of wry humor.
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