Removing Fuel Tank from a 99 203???

[sarmst100]

Is this thing bolted down or does it just sit in there? I'm working on re-carpeting and decided while the lids are off to remove the carpet and glue back there and spray it light gray. I only have a little fuel in the tank but I ran out of empty cans and the truck is full.

[Champ203]

It just sits in there but good luck removing it. I have to believe that they put it in before they secure the top cap. Never could get mine out when I was trying to replace the livewell pumps that are accessed in front of the tank via a carpeted cover.

Maybe someone with more smarts than me will be along shortly.

Peace,
Don<><

[sarmst100]

Mine has been out before but a shop did it but I'm not sure how they did it. I may try again tonight if I can get the rest of the fuel out.

[sarmst100]

In case anybody needs to know I finally got it out. First remove the charger and the access panel at the front of the tank. It was wedged in pretty good. Then pull up one the front of the tank and if it is like mine there isn't enough clearance to get it out. Remove the trim front the edge of the compartment so the rubber won't grab. Then snatch it as hard as you can from the front. Hopefully something will flex enough that it will come loose. Then pray that your sending unit works when you get it back together (don't trust those things always).

[Lunker Punker]

Did you get it back together okay? Im starin at mine and cant figure this damned thing out. Its just wedged in? How did you pull it out? Just wonderin if i need a crane or something

[sarmst100]

I siphoned also all the fuel out first. Then I disconnected all the hose and wiring. You will need the compartment lid off also. Then standing on the back deck, I worked it back and forth to get the panel out with charger on it. Once that was out I snatched on it pulling at the front of the tank. I had to jerk pretty hard.

I'm re-carpeting (probably should say removing glue) and haven't made it that far yet. The whole boat is in pieces right now. Be careful with your charger. The cap gets brittle over time and mine is crack in a few spots. I have a new cap coming from Dual Pro.

It should go back in. It went in before.

Good Luck!!

[Lunker Punker]

Thanks! I am in the same position with my 99 203 in pieces also. Why on earth they put that carpet back there boggles me. Then again I hate carpet period. I also dont think im gonna put the access panel back either so i can always have access to my aerater. That panel was a pain in the butt to get out. 2 pry bars a block of wood and a hammer it finally came out. After i ripped the carpet off there were four holes about 4 inches in diameter cut out of it. Dont know what those are for but dont really care. You really learn a lot about your boat when you go through all the little nooks and crannies. I keep finding stuff to fix. Let me know if you get that tank back in and thank you for the help!

[jerzia]

Same here. I'm going to put the plate back in eventually, but put in an access door for the pumps. Also, I removed the carpet from the bottom of the plate to the top of the tank. Later models had a removable access from what I hear.

[sarmst100]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Lunker Punker &raquo;</TD></TR><TR><TD CLASS="quote">Thanks! I am in the same position with my 99 203 in pieces also. Why on earth they put that carpet back there boggles me. Then again I hate carpet period. I also dont think im gonna put the access panel back either so i can always have access to my aerater. That panel was a pain in the butt to get out. 2 pry bars a block of wood and a hammer it finally came out. After i ripped the carpet off there were four holes about 4 inches in diameter cut out of it. Dont know what those are for but dont really care. You really learn a lot about your boat when you go through all the little nooks and crannies. I keep finding stuff to fix. Let me know if you get that tank back in and thank you for the help! </TD></TR></TABLE>

Sounds just like my plate. I think they used whatever scrap they had laying around. I going to clean up the compartment and paint. I may replace that plate with a piece of polished aluminum tread plate I found hidden in my brothers shop . I'll probably just make it large enough hold the charger and cover the hole.

[sarmst100]

I'm also installing two Bluewater LED livewell lights while this is all out. You guys might want to look into these since your that deep into it already and they are dirt cheap IMHO. Here's a link to the lights and installation. I bought white and blue ones, but I think the white is better for the livewells:

http://bluewaterled.com/catalogdetails.php?id=26

http://www.day-vizinstall.blogspot.com/

[Lunker Punker]

i already have the led lights from bluewater ready to install Im line-xn the trailer and the deck under the consoles. I bought a bunch of leds to go all over the place once the heavy stuff is finished. Lots of work but well worth it!

[sarmst100]

Cool! I don't think I will ever get all this freakin' contact cement off from the old carpet . I may try paint stripper on the lids.

I just drilled the holes for the livewell lights but forgot the silicone to seal the holes off.

[Lunker Punker]

Acetone works well but where it is real thick tthere is a few things that work better. 3m has a paint stripping pad sold at lowes or home depot that fits any drill. This works very good. Where the glue is really thick i used a drill with a wire brush wheel. Its time consuming but it will be worth it! Once the glue is gone you have a well scuffed surface for the new glue to adhere to. If the prep is done properly your new carpet will never seperate or lift from the deck.

[sarmst100]

I've been using a 4 1/2" grinder with a wire cup brush but it still leaves some glue that is hard to remove. Should I get 100% of the glue off? I used MEK and acetone on the gelcoat with a scotchbrite pad and it worked pretty good.

[Lunker Punker]

you dont have to 100% of the old glue off. The more you remove the better. What type of glue are you planning to use? If you are using something different than factory carpet glue the more you get off the better. Im a bait airbrusher so my surface is totally clean. Doesnt matter as much with carpet glue but i just cant leave old material to go over. Plus its uneeded weight.

[sarmst100]

I'm using contact cement on the lids. I may use in on the whole boat. That's what they used at the factory except on the floor, they used some type of glue down there.

I would like to get it all off but after wire brushing it there is still a film on it that still doesn't come off easy with acetone or MEK.

[Lunker Punker]

Let it dry out for a while and go back over it with a sander. Stuff doesnt like coming off but it will.

[Reno1]

How about a 1986 Champion removal of tank? Thx

[Tx Champ]

How about a 1986 Champion removal of tank? Thx

The 86 tank probably sits 180° to the 99, but the process is going to be about the same. See posts #4 & #6