John,

When I made that statement about “the worst job” I was only thinking about a Nor'Sea 27 and the related jobs on that boat. Sorry to make you wince.....

If you do not have corrosion on the outside of the tank, I don't think you will need to change it.

At the time I was working on my tank, I found a couple of types of tank quantity systems and each one had a different sending unit with a different way of mounting it.

As for the access plate, if you search the web, you can find ready made ones of different sizes. You just purchase it, cut the round hole, clean the tank, and install 2 half moon shaped parts that fit inside the tank (through the hole you just cut and your done.

I used bronze fittings, but used a good coating of a thread locking galvanic isolation compound. I don't remember the exact name of the product just now. You can do a web search. It's the same thing I use on my SS hardware that goes into my mast. So far, years later, it's all good. BUT, as it's in that clean-out top plate, I'm not worried if they ever go bad. I can just change the plate for a couple of dollars.....

My fuel pick up is a solid tube about one half inch off the bottom of the tank. I wanted to make sure I did not pick up any water or crud if I get some. I also was planning on a tube reaching the bottom for a sample of bottom fuel, but never got around to it. The other thing I did was to put a length of tubing (like aquarium tubing) inside the tank from the fuel return fitting. I put a weight on the end to keep it at the bottom of the tank. I did not want the foaming that can take place when fuel returns to the top of the tank and the tank is less than half full. Not sure if it has ever helped, but it made me feel good and only cost a couple of bucks.

Since we put in the new fuel system we have not had ANY diesel smell in the boat. Jill is VERY sensitive on this point!

The new tank has a grounding tab on the top close to the fill fitting I did ground it to the engine.

Hope this helps.

Greg