Leaking fuel tank repaired : Carver 4207 w/ CAT 3208s.

We repaired the starboard aluminum tank by installing an access plate near the aft end (transmission end). Gaining access and machining the side of the tank to receive the access plate took more time than repairing the leak itself. Once the access port was ready, we cleaned, patched and sealed the tank bottom on the inside – then closed the access port.

Access was awkward but do-able. The leak and the cause were obvious. Compared to other methods, the repair was relatively inexpensive. If the repair materials were accurately described by their manufacturers, we have high confidence in the result. If it is ever necessary, it appears that the same repair could be done on the other tank.

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Because of poor tank access at the rear of the engine, I began the job by hiring a small mechanic to remove (and eventually re-install) some engine parts -- the exhaust pipe was particularly stubborn. His labor was 6 to 8 hours.

Other than that, I did the work. My part took two weeks and about 40 hours (estimated). The cost of parts, materials and tools was under $1000.

Even with the engine parts removed, access is quite restricted -- the job is best done by someone 5’10” / 170-lbs or smaller. It will help if the repair person has considerable experience in multiple areas of boat repair.

If you would like full details, send an email request to kreed60950@gmail.com.

Bob / zigzag