Careful in thinking that moving the tank forward will change CG. This is only true when there is fuel in it! Without fuel it doesn't change CG, and you don't want the CG to change with more/less fuel.
I removed the entire floor, not just the outer skin. Going to replace it with coosa, laminated both sides. Check out Peter Allaires rebuild in the photos section of this site, very helpful. I think the job will actually be easier this way, instead of re-coring the existing deck. Plus, what I found underneath the sole makes me even more glad I'm doing it this way, another 50 lbs of useless putty and foam gone!
Going with a 40 gal Moeller poly tank (ft4037). Will fit right between the stringers. Build and install small bulkheads forward and aft of tank to secure it, just like in Peters pics. Paint all with Bilgekote and cut access hatches in the new sole to have access to the entire bilge, which will be really nice. Should be able to keep the boat bone dry, no more inaccessible areas where water collects.
With 40 gal of fuel, getting around 2 gph cruising @ 25 kts, should give me a range of 20 hrs/500 miles. Plenty! Just guessing on the fuel burn from some research on other boats... Maybe won't be quite that good but I expect no more than 3 gph @ 25 kts.
Likely going with a 135 Honda. Going to go look at it today. My mechanic says they're the best for reliability and lifespan. Did the 2 stroke thing for 3 years, but now the old Mariner needs a lower unit, and compression on #2 cylinder is low. Plus, it's hard for the wife to start/run and she hates the smoke/smell. So, 4 stroke it is! Happy wife happy life!
I have to say I am looking forward to a sewing machine quite engine...
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