Need Help with Fuel Leak!!

Green Machine · 02-19-2005, 02:48 PM

My worst nightmare has come true.....came home from fishing, pulled the plug on the boat, and out comes about a half gallon of fuel. At first I thought it may be a line or the fuel/water separator, but now I am pretty sure it is the tank. I checked all the lines and fittings.....look great. Filter is on tight and dry. I jack up the tongue as high as I could get it and fuel starts to roll to the transom. I thought it may be extra fuel that got pushed to the front of the boat when the plug was in and i was running, but the leak continues. It is about 2 cups an hour and the tank is about 2/3 full. I pulled the floor up(quite a task!!) and the tank is secured by welded cross members. I don't know how I'm going to get it out, let alone make sure this is my problem. Any help and input would be greatly appreciated. The boat is a 99' TJ Alexis. Kind of weird, but the tank says 110 gallon capacity. It is aluminum.

Thanks,
Green Machine

snit · 02-19-2005, 05:50 PM

Are you the original owner? If so, then I'd be on the horn to TJ. Actually, I'd call them regardless, and in a real sweet way, expalin the problem. There's a good chance that they may "make-it-right" with you. It might cost you a trip to the factory but that way it would be repaired to oem standards. I'd stress to them the importance of this matter, and I'm sure they know about the hazards of gasoline and boats.

Green Machine · 02-19-2005, 09:06 PM

I am the second owner, but will take your advice and call on Monday. I can't see how this would be operator error or fault. The tank is surrounded with expanding foam....no way to puncture it??? I am really sick about this one.

Green Machine

Tacklebuster · 02-19-2005, 09:56 PM

That sucks....
Sounds like that foam probably is saturated with fuel as well. Let us know how that call goes.

1pump · 02-19-2005, 10:14 PM

Yikes!

I'll second the motion to call TJ. I'd emphatically mention 3 things to them:

1. Fire hazard

2. Enviromental hazard

3. Huge liability potential. Much cheaper for them to fix it now rather than lose a costly and well-publicized lawsuit later.
I'm sure they'll try to deflect it at first, but with the proper "persuasion" they'll make it right. If they have any business sense at all, that is.

MacEFL · 02-20-2005, 06:32 AM

I had a fuel leak in my Smokercraft. I towed it down to Stayton and explained the problem. The boat was NOT under warranty. I had already pulled the center floor board. When the guy walked up to the boat he said that he smelled gas. A week later he towed it up to the Sportsmans show with a new tank and fuel lines! I was happy! While it there found my bilge pump had a big crack in it. Replaced that at cost, no labor!!!

BigMac · 02-20-2005, 10:07 AM

I had a leak last year on my Northwest Jet, and it was the fuel pump. The screws holding the two halves together had vibrated loose about a 1/8 th turn. I removed the screws applied locktite problem solved. I would guess that the leak is coming from the motor compartment, not the tank.

Green Machine · 02-20-2005, 12:58 PM

I was hoping it was the fuel pump or water separator, but gas still keeps coming out from below the tank when it is tilted up. Is there a way I can test the tank?? Thanks for the help guys, I need it on this one.

Green Machine

1pump · 02-20-2005, 01:58 PM

The only test I can think of is to plug off all the outlets, return lines, vents, fillers, etc and pressurize it with maybe 5 lbs of compressed air and a leakdown gauge. That's how they test tanker trucks, anyway.

I realize that it's easier said than done, especially when the tank isn't designed to be tested easily. :depressed:

Two Fister · 02-20-2005, 10:47 PM

Green Machine,
Use extreme caution if you try to pressurize your tank. It takes very specialized equipment to pressurize tanks that contain highly flammable vapors. It is almost certain that you will generate enough static charge to create a spark capable of igniting gasoline vapors. If the foam within your bilge is saturated with gas this could create a very dangerous situation long after all of the fuel is drained from the tank. Remember that gasoline is most dangerous when it is in vapor. One gallon of gasoline in vapor has the explosive potential of 20 sticks of dynamite.

If the foam is saturated in the confined space of the bilge, it could produce an explosive atmosphere for a very long time. If the bilge is closed, the gasoline vapors will build up until the hatch is opened. The resulting introduction of oxygen will create the perfect conditions for a catastrophic explosion.

I would take this back to the factory or an authorized representative ASAP.
TF

Green Machine · 02-21-2005, 08:14 PM

Oh brother......This has turned into a bigger problem than I thought. :depressed: I talked with the factory today and after I get them my tank information tomorrow they may help me out. Sounds like if I lived in Lewiston it would not be a problem, but I don't. I'll keep you posted and thanks for the help. I'll either love Thunderjet or will be protesting them soon.

Green Machine

Two Fister · 02-21-2005, 09:50 PM

Better to be safe than sorry! Every year people get badly hurt or killed because of bilge fires/explosions. We get used to gasoline because we are around it so much. It's easy to get jaded to the dangers presented by something familiar.

From what I've heard, Thunderjet is a good company to work with. I'll bet they take care of you on this matter.

If you have gotten the fuel out and want to know if the gas vapors are gone as well give the guys at the local fire house a call. They have an explosive gas meter that will tell you if the vapors are gone.

Good luck!

TF

snit · 02-22-2005, 06:49 AM

Stick to your guns! I think they're a pretty good company, as long as you're speaking to someone who has some authority to make financial decisions. It'll probably cost you a trip to Lewistown, but maybe you will get them to deliver it back to you after it's fixed? Good luck, and I wouldn't be afraid to mention that you've posted the problem on the net, and everyone agreed that you should contact the factory. Let them know that they could be dealing with a PR nightmare (in a very subtle way), if it's not fixed. Good luck!

Green Machine · 02-24-2005, 08:07 PM

I'm transfering this to the ifish community board.

Green Machine