Fuel tank

[ocuyler]

jedgar,

This project is easiest if "attacked". Remove the hatch, disconnect and/or remove the hoses, use a 12" sawlsall blade to cut the foam away from the tank. You may have to trim the hatch lip as described above. If you are replacing the tank, you can remove the sending gauge and use that hole to put a small bar inside to attach a strap to, to pull that end up and out first. Once you get it started, a helper may come in handy.

Additional comments: You may consider installing 2 tanks vs. one. Be sure to evaluate the ply under the tank. As long as you’re in there, replace it, if needed. Pascoe's tank installation method is generally accepted here. It allows the tank to breath on the bottom. Be sure the fuel tank cavity drains, too.

Finally, take a good look at the stringers while you're in there. There should (must) be a weep hole in the aft most end at the bottom to drain and water that has worked its way into the foam. Any screw holes left from attaching the tank hatch, leaning post, etc. need to be drilled and filled with epoxy. Using 5200 as a bedding compound putting those screws back will prevent water integration in the future. This is the primary reason these tanks go bad in the first place.

Best of luck.