2002 2870 Gas Tanks Leaking

[maitman99]

I have a 2002 2870 Express that has a leaking gas tank.

The new tanks are ordered and should be arriving soon.

My challenge is the removal of the floor. Called the factory and asked for their advice on where and what to cut and they were not alot of help.

Has anyone removed the floor of a 2870 or similar model? This floor is not the two piece floor, it is one piece and a part of the deck mold, so we will need to do a bunch of cutting to get the floor up (going to try and save the original floor) There is also a center support between the tanks that I think is bonded to the deck with the dreaded 5200.

Any help or info would be appreciated, I am really worried about this challenge

[maitman99]

There was certainly a hole in the tank.
Strange location for a hole, high and on the side of the tank.
Port tank was about to start leaking in the same spot.

Boat tank 1.jpg

Boat tank 2.jpg

boat deck.jpg

[Idi_Amin]

Wow!!! That is unsettling because your boat is not very old (2002 is not an older boat in my book).

1. How did you know it was leaking?

2. How exactly did you get the floor up so you could remove the tanks?

3. What did you do for a replacement and did you figure out what caused the hole/leak?

Thank you for sharing!!!

[maitman99]

Suspected a leak first when there was a strong raw gas odor in the cabin and lazarette and then I found gas in the bilge.

Removing the floor was an unbelievable pain. Cut around the perimeter of the floor including a portion of the vertical parts of the rear sections. After completing the perimeter cut, it became obvious that the dreaded 5200 was used on the center vertical bulkhead. The only way to get past the 5200, was to cut the floor right down the middle. My floor is now in 2 parts. Pursuit builds a great boat, but they never thought that anyone would have to replace gas tanks.
I am going to teak the floor after it is reinstalled, if I don't, the non skid will be a real mess.

Not sure why the tanks developed the holes, no abrasion and no trapped water. Overall the tanks are in rather bad shape for 13 years, of which 8 were in fresh water.

A challenge I am having not related to Pursuit is that the work is being done in St Thomas USVI. The fiberglass crew took the tanks out and then disappeared, my boat is now that torn apart junk boat that sits for weeks in yards everywhere. I am flying to St Thomas on Sunday to see if I can get the project restarted and finished. If I cannot get the locals to reappear, I am considering flying a glass expert from the mainland to St Thomas to finish the boat. I have a beautiful home and a great car they can use while they make my boat whole again.

[offshore2870]

I just completed same project on my 1997 2870 Offshore. I would suggest that you have the tanks painted with epoxy paint before re-installing. Also, I installed new 1/4 inch Neoprene rubber strips to provide better support and cushioning under the tanks. While you are at it, replace all the fuel lines. If you lost the old tanks, Pursuit can provide you with the dimensions needed for the construction of new tanks. Just call their customer service dept and give them the hull ID number. Removing the cockpit sole was indeed a PIA and you need a good glass man to make it look right after the job is done. You would never know my deck was off at any time. Good luck!

[maitman99]

Did get the specs from the factory and had the OEM manufacturer build new tanks with an epoxy coating to the original spec ($3k plus).
When they pulled out the old tanks, it became apparent that we should replace the bulkheads for and aft of the tanks.
The plywood was starting to delaminate, so it seems like a good idea.
We will replace all hoses valves etc. the tanks came with new sensors installed, so it will be great to have accurate gas gauges again.
My problem is not the work that needs to be done, its the workers that are doing the work.
The boat is on St Thomas USVI and the "local fiberglass guy" thinks two or three hours every second day is going to get the job done. I just returned and in the week that I was there, he had removed the forward bulkhead and fabricated its replacement, just fabricated it, has not installed it. At this rate my boat will be ready by Halloween.
My second concern is the floor. To remove the floor it was cut into two pieces and they had to cut up into the rear lazarette and cupboard. The non skid will never match the rest of the boat, so I am actively shopping for a teak or fake teak solution that I can use to cover the replaced deck. Anyone have ideas?
Keep you all posted as the snail yard progresses.

[s2jk6565]

maitman99,

My 2002 2870WA now has the starboard tank leaking. I tried calling Pursuit, they are only 30 miles from me. They will do the work for $30k and 6 months from now. No help on tank costs or availability, drawings etc. I am lost on what to do. I'll be bringing the boat to a local boatyard. Do you have other photos you could share? I am especially interested in photos of where to cut. Let me know, thank you.

[uriami]

I have the same problem with my 2002 2870, I ordered 2 new tanks, is any one have pictures of the actual deck cutting area.
Thank you all for all the information.

[medelman2k]

I am curious to know if these boats with gas tank leaks were dry stored or in the water?

[BiscuitwantsaPursuit]

My new to us 1997 2870 Offshore CC had the rear tank fail before i bought last month. The owner had already gotten the exact tank from Pursuit (They use Florida Marine- same as the original)
So when i bought it i knew what i was in for thanks to someone on THT that had documented his same project with pics- Lifesaver.
My deck comes up by removing screws topside then pulling deck up. I had to trip the lip the deck sits on about 3/4 of an inch to get the forward tank out and had to removed the bait tank leaning post to get the forward tank out. Then cutout the bulkhead separating the fore and aft tanks within the fuel coffin in order to get the rear tank out that had failed.
I also found the floor of the fuel coffin had rotted out completely and had to remove and regales in a new one.
It was a messy job but certainly not a 30k job as someone has run into above. They must have a different model 2870 that doesn't have a deck lid.
I replaced the fittings, etc
All is good now with tanks- The leak was at the front starboard bottom where the tank rubbed against the hull. It had corroded and made a pin hole leak.....
Chaffing strips of neoprene and if you want to keep it another 15 years then coal tar epoxy them before install