gregpatent

Thank you everyone for your helpful suggestions. I removed the tank and found the leak was caused by a deck screw puncture in the top bow end of the tank, which is why it only leaked when the tank was full. A former owner installed a 1x2 over the bow end of the tank and screwed a deck screw into the top of the tank. When I turned the tank on its end, the gas remaining in the tank poured out of the hole. I am weighing whether to patch the hole by JB Welding a small piece of aluminum over the hole or buying a new tank, provided I can find one at a reasonable price that comes close to fitting the hole. Other than the puncture, the rest of the tank, including the bottom, looked okay. All of the hoses need replacing. The filler hose was dated 1984, the same year I saw my first Yes concert.

Thanks for replying -- I'll try it. The fill hose is old but doesn't have any visible cracks. I believe it's expensive, but certainly cheaper than blowing myself up.

I have a 1985 Glastron I/O with a 30 gallon aluminum gas tank. I filled the tank for winter storage, and sometimes when I pull the boat on the trailer, I find traces (about 1/4 cup) of fuel in the bilge. The filler hose, vent hose, and supply hose are either new or look okay. I also do not feel any wetness on the connections to the tank, the water separator, the transom vent, or low points in the hoses. Is there a way I can safely find the leak without removing the tank and visually inspecting its entire surface, which requires me to remove a portion of the deck, not to mention 30 gallons of fuel? The boat is primarily used in salt or brackish water, and I am not sure how aluminum tanks do over time in such environments. However, if I had a leak in the tank, it would seem that it would be in the bottom where it contacts bilge water and that I would have more fuel in the bilge than 1/4 cup. Any suggestions?