Aluminum Fuel Tank Replacement for Boats

Why Boat Owners Choose Aluminum Fuel Tanks

We recently completed an aluminum fuel tank replacement for a center console boat that came in with a leaking steel tank. The customer brought us the old tank, and we used it as a pattern for the new design. Because we work from either old tanks or detailed drawings, we can match mounting points, fittings, and size. This approach helps the new tank drop back into place without surprises.

Material Thickness and Coast Guard Standards

Most custom boat tanks use .125″ aluminum plate. We follow this as a minimum even when the original tank used thinner metal. Larger tanks may need thicker aluminum for extra strength, and we size the material based on length, width, and height. In addition, all of our custom fuel tanks for boats are built to United States Coast Guard guidelines and pressure tested before they leave the shop.

Fittings, Senders, and Fuel Lines

Each tank includes a fuel fill, fuel vent, pickup tube, and sending unit. The sender ties into your fuel gauge so you can keep an eye on fuel level. For diesel boats, we often add a return line as well. Fill tubes are typically 1.5″ and vent tubes are .625″, which match common hose sizes. Because we weld the fittings in-house, we can adjust the layout to clear deck hatches, stringers, and rigging tubes.

Freight Shipping and Measurement Options

We are located in Wilmington, NC and many local customers drop off their boats or old tanks. However, we also build tanks for out-of-town boaters. You can ship us the old tank or email drawings with key measurements, then we send the finished tank back by LTL freight. When you provide clear photos and measurements, the process stays simple and the tank fits like it should.

Order a New Aluminum Boat Fuel Tank

If you need an aluminum fuel tank replacement or a new tank for your boat, start by visiting our Fuel Tanks page. Then reach out through our contact page with drawings, photos, or basic dimensions. Our team will review your info and walk you through the next steps. To see more of our marine fabrication work, watch our fuel tank video on YouTube.