[Frustrating Continung Water-in-fuel Issue]

I would appreciate some advice regarding a continuing, frustrating water-in-gas issue.

My year 2000 115 Johnson's plastic, permanent gas (Wellcraft 190 Fisherman) tank became mostly filled with water (some gas) after a huge rain storm, because I had left the deck cap off and was in the middle of replacing the fuel sending unit. I pumped out what I thought was all the water in the gas and refilled. The engine ran fine after draining the carbs - until I water tested it and the boat tried to plane. I guess the remaining water settled to the bottom rear of the tank and was picked up by the pickup tube. Not successful.

Next, I drained the tank completely - after placing the boat on a sharp angle to force all liquid to the rear - and added a few gallons of fresh gas. Again, the engine ran fine on the hose and at the ramp, but I still had the water issue while trying to plane.

Then I went into the tank through the top-sending unit hole and sucked what little else was in there using a copper tube attached to a siphon hose, attached to a primer bulb. I stuck pieces of towel in there and mopped up what I could see that was left.

We rebuilt the carbs, changed the fuel filter several times and added a few gallons of fresh ethanol gas. Success! I then added 6 gallons of non-ethanol gas (at a marina, at $4 per gallon) and had a great day on the water.

Friday, confident the problem was behind me, I added around 9 more gallons - this time from Wal-Mart (ethanol) and took the boat out. It ran great, until I tried to plane it and had the same issue. I pumped out the tank again and found a gallon or more of water in there. At least I think it was water. The substance appears whitish/cloudy and sits at the bottom of the gallon milk jug into which I siphoned each gallon. The gas is yellowish and rises to the top.

So, water is getting in (is in there somehow), but how?! The sides/bottom of the tank do not leak because gas does not leak when I add it. The vent has been the same and the boat has been used and stored the same for eight years. I see/smell no gas in the bilge.

The deck cap above the sending unit is old and the boat has a closed transom, so water does build up around the deck cap for short periods of time during/after rain and when cleaning. Water could be getting onto the top of the flattop tank. We had a lot of rain the night before my latest disastrous water test.

Could water be leaking through the deck cap (old O-ring) onto the sending unit, which is properly installed but old (maybe a bad gasket)? Could the top of the plastic tank have a crack (unlikely?) and be letting rain/wash water drip down into the tank? Wouldn't that be the least likely place for a leak?

I am frustrated beyond belief - especially after rebuilding the carbs and doing a complete tune-up.

If it's the tank, How much am I looking at to have the 60-gallon tank cut out (easy to access) of the deck, replaced and re-glassed? I am in Southeast Florida.

Thanks, all.

Update: I bought a portable tank and filled it with ethanol gas and ran it to the engine, via the water separator. I had no trouble with the engine on Sunday. So, it's not a motor issue.

For the first time, though, I smelled gas. I figured it was because of the portable tank or the bilge (in which I had spilled a little gas while changing the fuel filter). Then I opened the floor hatch just in front of the center console and got a strong smell of gas from there. That area is well forward of the gas tank and fuel lines. I guess there is some gas in the hull that hasn't made its way out yet. The boat allows drainage to the front when hooked to my truck.

I put 3 1/2 gallons of gas in the inboard tank with the thought that I would try using it today, but we were having fun and I did not switch to the inboard tank. I will siphon out that gas and see if all the gas is still there. If there is a leak in the lower part of the tank, it's a small one.

I would appreciate references on people who will cut out my tank and replace and re-glass it.

I have heard it is not wise to mix ethanol and non ethanol gas.

[New Jersey Members]

I fish out of Barnegat inlet as far as the ridge, so far.