ian and Forum folks tracking the holding tank extract project ----> Done.
Was a one-guy job, taking about 5.5hrs. 3 hrs to do the main cuts, 2 hrs to do the follow-up cuts (discussed below) and about 30 min to wedgie out the holding tank. Pics attached.
Will post a dimension-specific drawing of the cut lines related to fixed points on the sole for others to use.
Dimension of the cut is 22.5" by 33 .75".The cut lines lined up exactly with the inside wooden frame of the holding tank sub compartment.
Pic1 - shows the depth of the cut and near perfect alignment with the bulkheads/timbers. The sole is a composite glued together 1 3/8 thick teak, marine plywood and fiberglass section. Under the sole structure, with a 1/2 air gap, is a 1" x 1.5" wooden subframe that secures the top of the holding tank to the boat frame. The subframe is glued (as Karsten at IP said...with very liberal application of 5200 everywhere) and screwed into the bulkheads (with SS screws) and fore/aft running timbers. The tank has about a 5/8 air gap all the way around from the bulkheads/timbers.
Pic2 - shows the sub-frame that I had to also cut away from the bulkheads and timbers. we had an extra fun time. The "liberal amount of 5200" included filling the air gap between the bulkheads/timers and the sole which added a dozen more "screwed-in like" points that glued the sole to the sub-frame. Lots of fun. Once the subframe was removed, the tank moved about easily in the sub-compartment.
Pic3- I slid a strap down one end of the tank, and worked it under the tank. Used the strap to lift, and the attached suction handle to pull the tank out of the sub-compartment.
Pic4-yes the hole. a little over 1.5" hole in the aluminum tank. Guy next to me is metal guy, and said the aluminum should not have failed like that. Maybe a weld seam, but not a flat surface. Will get with Hayden to see what we should present to IPY to work with Florida Marine Tanks, the manufacturer. Too many of these failures in the same place.
Pic5- subspace cleaned and ready for the new tank that arrives Tuesday next week. Will paint the interior of the sub-compartment with a couple coats of epoxy paint (IPY only painted the section directly under the tank). Will smooth the edges of the cut-out section, and glue 1/8 birch strips to finish the access door frame in the sole and to finish the sides of the sole section I removed so they are framed out to look they same as the other access panels in the sole. Will keep you posted.
Update 14 Oct
Just received the new tank from Wellington plastics, BC Canada and measured all the exterior dimensions, and hole locations. Appears spot-on. Also note the access lid included. The tank as the baffles on each side identical to the original Florida Marine Tanks installed as OEM. Will complete the installation this weekend.
Pic 6 is picture of the unserviceable aluminum tank next to the new poly tank.
Pic 7 is the aft side of the new tank, showing location and extrusion of the fittings for the plumbing.
On a separate note, I contacted the customer service folks at Florida Marine Tanks, Inc, and got forwarded to the VP and GM. A surprise. The OEM tank they provided IPY had a 1-yr manufacture warranty; the warranty specifically excludes any damage caused by corrosion. So. Hmmm. Been scratching my head a bit why this brand was selected. Florida Marine Tanks offered to replace the tank at a reduced price. However, when I spoke with K
arsten at IPY Customer service and in his follow-up emails, Florida Marine Tanks was not one of the three recommended vendors.
Chess and Karen
The Belle of Virginia ... without the smell now.