removing foamed in gas tank

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vic33004

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27361
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any suggestions on how to remove an existing aluminum gas tank that is foamed in place? In this instance its in the hull of a Novurania tender. good access from the top, but almost no access down the sides. about a 1/2" on one side less than this on the others. there are 3 rows of foam holding down the tank about a 10 gallon tank. from what I read, polyurethane foam once cured cant be dissolved with solvents. I tried a piano wire (fishing steel leader). snapped way before I could get enough tension on it to cut the foam.

thoughts?
 
I removed a foamed in place (FIP) tank from a 23' Formula many years ago. I don't envy you. The biggest issue is the foam doesn't so much adhere to the tank, as it creates a vacuum as it cures.

First and foremost, SAFETY!!! If you can get to the fuel sending unit, remove it and gas free the tank. Fill it with water or let it air out for several days.

I would recommend removing as much foam as possible from around the sides with an electric carving knife. Wear gloves. That stuff sticks to everything!!

Get a PVC Cable Saw. Depending in the length you require, you may need two. If you do need two, cut one end off each saw and join the two with a square knot.

If you have a helper, and if the tank has a lip, use something as a lever and have the helper apply upward pressure on the tank via the lever as you cut it with the cable saw. It's painful because too much pressure and your lever breaks but not enough and your efforts get halted. But once the vacuum is released the tank will darn near pop out on it's own. It took me 2 days to get an 85 gallon tank out of my Formula. Actually, it took me 30 minutes and a couple of broken shovels (leverage).... It took two days to figure it out.

HTH.
 
Try a wood saw. The hard part is getting it inserted all the way but if you have to, you can make several shallower cuts. You're gonna have a lot of trouble if the bottom of the tank is foamed in place, too. I was replacing my stringers so I could get at the bottom. I'm really not sure what you can safely do in your case.
 
dry wall saw or pruning saw they cut on the pull stroke? too bad there isn't enough room for chain saw.
 
Long drill bit with an extension, literally chew it up in place.
 
thanks for all the ideas. the foam is under the tank, almost none on the sides.

I called the local dealer and found a tech there that has done a few. the upshot is it had to be cut out in pieces with a high speed cut off blade. fortunately the tank is aluminum so it wasn't hard to cut.
 
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