Swift Trawler 44 - Forward fuel tank leaking diesel

The friendliest place on the web for anyone who enjoys boating.
If you have answers, please help by responding to the unanswered posts.
See posts with no answers
nhislander

nhislander

Veteran Member
Joined
Nov 23, 2019
Messages
33
Location
United States
Vessel Name
No Regrets
Vessel Make
Swift Trawler 44
Just need some advice... Had two mechanics diagnose a leak in the weld at the bottom of my forward fuel the tank. The boat is a 2020 Beneteau Swift Trawler 44 with just 400 hours on it. Is there any way to repair a leaking tank vs. having to remove/replace the tank?

Talk ensued about the monumental (many month... six figures...) repair task as follows:
- Emptying the tanks.
- Removing floor of the boat (not even sure this is possible).
- Removing both motors...
- Removing the aft fuel tank
- Removing the leaking forward fuel tank
- Have a new fuel tank built/made
- Re-assembling the entire boat...

Just seems overwhelming to me... I think the fuel tanks are aluminum? Is there no way to repair a leaking tank?

Thanks in advance for any help/advice you might have...
Dave
 
Yikes! Is there no manufacturer's warranty that covers this?

I have seen tank "liners" mentioned on this forum...but typically for 30+ year-old boats. Yours is still, basically, NEW!

Good luck with this!
 
There are some products that are claimed to seal leaking fuel tanks, I don’t know if they work or not. I would start calling companies that polish or service fuel tanks. They may know someone that does this kind of work. Leaking fuel tanks are pretty much the worst thing short of an engine rebuild that can happen to a boat. Good luck.
 
2020 - oh boy might be cutting it close. Beneteau has a 3 year parts and labor warranty.

https://www.beneteau.com/us/service/beneteau-after-sales-service

Good luck. You may want to mention the 10k members of this forum are keenly interested in the disposition. Not sure if tanks are structural, but there's a 7 year warranty there.

You may want to get a good surveyor ASAP. Talk to your insurance agent as there are surveyors who specialize in assessing claims.

Peter Screenshot_20221108_135146_Photos.jpg
View attachment 133552
 
Last edited:
I’d guess the insurance policy would have an unforeseen circumstances or similar definition language. Your insurance group should be apprised of this and go after Beneteau.

If it as you describe imminent safety and peril language applies too with the builder likely on the hook to make good or replace the boat.. Get tough and good luck.
 
You mentioned damage from Ian earlier. Is there any possibility there is a connection?
 
There was a long running thread over on Yachting and Boating World (UK) motorboat forum recently about the same issue in a similar aged 34’ Swift Trawler.
In the end Beneteau came to the party and the repair was done by one of their agents in the South of France.
The tank fail was the welded seams and the tank was replaced by a slightly smaller version so it could go back into “jam fit” space allowed.
A big drama for the owner during the whole protracted process which lost him a whole boating season.
 
Are there inspection hatches, or any way to add one? Then get inside the tank and repair from the inside? I would think that some very brief TIG spot welds with cool off time in between might be possible.... or not.
 
twistedtree said:
Are there inspection hatches, or any way to add one? Then get inside the tank and repair from the inside? I would think that some very brief TIG spot welds with cool off time in between might be possible.... or not.
Click to expand...

If it touches wood or fiberglass then the welding might catch them on fire. We had to weld some stanchion bases where the PO hit something. We had to put some 1/2” drywall between the base and the fiberglass so it wouldn’t catch fire. I am not an expert on welding but I would be cautious welding on the tank unless there is a good clearance behind the area being welded.
 
I, am sorry your leak.

Link ST33 leak case UK

https://forums.ybw.com/index.php?threads/fuel-tank-leak.575693/

NBs
 
Very definitely contact your insurance company AND Beneteau.
To me there is no way a tank should be leaking on a less than 3 year old boat.

I also strongly recommend against messing with the tank untill you have done so or you may mess up any chance of Beneteau looking after you.
 
Hi,

I remember that the owner of the ST33 said somewhere in that long post that the welding seam was insufficient and the leak had started from there over time.

this information could help, discuss Beneteau, why the self-inspection has passed, if this 44 leak is a welding problem


NBs
 
I’d be pretty surprised if it wasn’t a weld seam problem. Fuel tanks are a real pain to weld, especially big ones. So much opportunity for a pinhole in the weld.
Even pressure testing them can be problematic if you have big temperature swings.
 
If you can get to the weld use a ball peen hammer to stop the leak then use a sealer which is diesel resistant. Its likely you will not have access to the leak. The problem is getting anyone that will repair/cut an access hole etc because of liability issues etc.
 
8 years ago I had a fuel leak from a 3 year old aluminum tank in my 36 Grand Banks Classic. Felix Industries of Seattle (now Northwest Environmental Services, LLC) came to my private moorage on Whidbey Island to assess the problem. It was found to be an internal defective seam weld that finally opened to a length of 3/4 inch. 2 technicians spent 11 hours emptying, cleaning, documenting and repairing with a 2 part epoxy kit, sealing the bottom and sides to a height of 6 inches. The other starboard tank was given the same effort with no issues found but sealed for good measure. Inspection plates made this possible, but can be added if not originally equipped. The total cost was $2800.00 and to date no incidents of leakage. Investigate if a similar service is available in your area.
 
nhislander said:
Just need some advice... Had two mechanics diagnose a leak in the weld at the bottom of my forward fuel the tank. The boat is a 2020 Beneteau Swift Trawler 44 with just 400 hours on it. Is there any way to repair a leaking tank vs. having to remove/replace the tank?

Talk ensued about the monumental (many month... six figures...) repair task as follows:
- Emptying the tanks.
- Removing floor of the boat (not even sure this is possible).
- Removing both motors...
- Removing the aft fuel tank
- Removing the leaking forward fuel tank
- Have a new fuel tank built/made
- Re-assembling the entire boat...


Just seems overwhelming to me... I think the fuel tanks are aluminum? Is there no way to repair a leaking tank?

Thanks in advance for any help/advice you might have...
Dave
Click to expand...

Should be under warranty
However if not AND you can get to the area leaking, I have had success with grinding out and using JB weld (tank was drained first), that was years ago on a gas powered boat, the repair lasted till I sold it 5+ years. That being said I would be pissed that a 2000 boat would need that. Raise hell w/manufactuer and have it replaced, although that also has its disadvantages, IE: torn up interior, loss of use etc. good luck
 
first, wow what a bummer!

I would:
1. file claim in writing with beneteau immediately. Give them an opportunity to reply but if they start dragging feet email/call up the CEO of Beneteau america, then international.
2. read your insurance policy and see if it is robust and might cover as well in the event that beneteau wiggles out (they can subrogate against beneteau). many policies have exceptions for this sort of event but some high quality ones may cover!
3. get independent pros (mechanics are not who you want, probably a surveyor, or someone that builds fuel tanks) to document the situation in writing and allow the above parties access to inspect so they cannot claim you did not

questions:
1. if you have contacted beneteau, what has their response been?
2. do you have any more details of exactly where the leak is and pictures ?
3. who manufactured the fuel tank? are they still in business? are there any other reports? post up pictures of the info plate on the tank

thoughts:
- i would NOT want a bandaid repair, especially on a 2020 boat. likely surgery will be involved and lots of cutting and removing engines (ugh)
- i would consider replacing the other tank at the same time. if one failed, there is a chance the other one is compromised, if it is in fact a material defect, or installed improperly.
- consider using a different material for the new tanks
- the tanks are pretty elevated so unlikely they have been sitting in water. i am curious if a weld simply failed, or there is corrosion (internal or external), or an electrical issue (check grounds, etc)
- i feel like i read somewhere her or on facebook about this or similar issue, a few weeks or months ago. i dont know if it was you or you are just writing about this for the first time in the past week?
 
ps. i see you got your boat january 2020, so beneteau's warranty should still apply. pps. unless your boat toppled over, i doubt anything can be tied to hurricane ian damage. in fact, i saw the pictures you posted, i would not confuse beneteau, no need to mention, perhaps remove references.
 
These are tough problems and used to be quite common on Taiwanese built vessels years ago with stainless steel water and fuel tanks. But I wonder how were the “ two mechanics “ able to access and determine and locate a faulty weld which I’m guessing is a tank bottom seam weld. We’re they able to gain inspection access into the tank ? If so and they have actually located the leaking weld then perhaps there could be a topical patch. But I find it hard to believe these mechanics could ID a weld failure from the interior of the tank without access below at the exact location. And I find it hard to fathom a tank like this having access below or the sides for that matter. However you do need to determine the tanks material since aluminum would possibly easier to patch than stainless.

If you don’t receive warranty satisfaction from Beneteau and are contemplating an insurance claim there may be a possible avenue providing you have a true yacht policy and not some budget harbor craft or similar coverage. I’m thinking the ‘ Latent Defect ‘ clause. This being coverage for a builder’s or mechanic’s defefect that ‘ cannot be found by the insured using reasonable care and normal inspection or maintenance ‘ . If it is found to be a Latent Defect then underwriters will indemnify the insured for labor and materials to repair or replace but will not pay for the defective part. This will be a hard sell and costly so the numbers for such work must be worth it to you. This means you’ll need to remove the tank so an expert or qualified surveyor can do a technical weld inspection, if it is indeed a weld, and be able to prove its faulty and attributable to the builder and not some other cause. If not you’re on the hook for a new tank and all labor and materials

Good luck
Rick
 
Last edited:
Also make sure its not antifreeze someone sloppily spilled. I would want confirmation, pictures, and visual on the faulty weld/leak.
 
I agree that the first step is to talk to the dealer and Beneteau. In many states you can get them on the implied warranty of merchantability even if they claim their warranty doesn't cover it.



Failing anything there, it is possible to fix a diesel leak with epoxy, inside. Maybe outside -- worth a try.


We had two bottom tanks constructed in Fintry's #2 hold in England, 1,900 USG each. Bottom was the hull, ends and baffles mostly existing steel, but we raised the floor a foot (and still have 7.5' headroom). We were told that they pressure tested the tanks. One of them sprung a small leak inside the boat while we were crossing the Atlantic.


There's a human sized access inboard of the leak, but I had to cut a hole in a baffle to get at it. I cleaned it thoroughly with alcohol, then put on a thin base coat of West System, then a goodly amount of West System with 404 High Density Filler. That was in late 2005. Seventeen years and probably 10,000 gallons later it's fine.


Fintry is steel, but I wouldn't think aluminum is more of a problem -- in fact, there's one advantage, that you don't have to worry about sparks while cutting any required access holes.


Jim
 
Circumnavigator said:
I agree that the first step is to talk to the dealer and Beneteau. In many states you can get them on the implied warranty of merchantability even if they claim their warranty doesn't cover it.



Failing anything there, it is possible to fix a diesel leak with epoxy, inside. Maybe outside -- worth a try.


We had two bottom tanks constructed in Fintry's #2 hold in England, 1,900 USG each. Bottom was the hull, ends and baffles mostly existing steel, but we raised the floor a foot (and still have 7.5' headroom). We were told that they pressure tested the tanks. One of them sprung a small leak inside the boat while we were crossing the Atlantic.


There's a human sized access inboard of the leak, but I had to cut a hole in a baffle to get at it. I cleaned it thoroughly with alcohol, then put on a thin base coat of West System, then a goodly amount of West System with 404 High Density Filler. That was in late 2005. Seventeen years and probably 10,000 gallons later it's fine.


Fintry is steel, but I wouldn't think aluminum is more of a problem -- in fact, there's one advantage, that you don't have to worry about sparks while cutting any required access holes.


Jim
Click to expand...
I have not had a lot of success with epoxy for longterm adhesion on metal surfaces. Eventually an edge starts to lift and quickly leads to total failure. That said, tough to argue since the quoted experience above was obviously successful.

If going this route, would use something specially made for fuel tank coating such as POR 15

https://por15.com/products/fuel-tank-sealer?variant=39607017177255

Looking forward to an update from OP. Fingers crossed for a good outcome.

Peter
 
When working with Al, a careless welder can mix up welding rod which over time leads to corrosion of the seam area. Then comes the contact issues with Al whether dis-similar metals, piping, wire or debris from construction.

The key to any marine fuel tank is to design and construct the vessel so the tanks can be easily accessed and repaired when issues arise. Design 101 basics apply.
 
You must log in or register to reply here.

Similar threads

T
Hi I'm Tom
Replies
1
Views
242
Comodave
Comodave
L!fe48
Black Water Holding Tank Replacement / Repair
Replies
12
Views
2K
receptionraritaneng
R
C
Beneteau Swift Trawler 44 engine movement
Replies
3
Views
336
Comodave
Comodave
C
Beneteau swift trawler 44 starboard hand engine movement
Replies
2
Views
345
Pascall
Pascall
Coconut Runner
Caterpillar 3208 Fuel Injection Pump Symptoms
Replies
17
Views
1K
Ramblin Rose GB49
R

Latest posts

Back
Top Bottom