Remove Center Ballast Tank from 2002 SANTE. No gas tank removal necessary

[intrlaz]

Hey all,

I decided to remove the center ballast tank from my 2002 SANTE, and since I was going to scrap it altogether, I figured cutting it out would be easier than removing the gas tank, floor, etc.

Overall, the removal took approximately 2 hours.

The primary tools I used to cut the tank out were a Dremel Multi-Max tool, a jig saw, a chisel and hammer.

The first step is to remove the brackets holding the tank in place

[intrlaz]

Next, I slid the tank toward the stern and cut a large hole in the top with a jigsaw.

Generally, the jig saw would be my choice of tool if it weren't for the lack of accessibility. It makes short work of the plastic and doesnt leave a huge mess

[intrlaz]

Because the tank is installed below the floor, I had to cut out half at a time. Through the entire process, I made 5-6 cuts (excluding top cuts with the jig saw)

This picture shows the result of my first cut.

For the long cuts on the bottom of the tank, I used the semi-circular blade on the Multi-Max. I also shoved some small pieces of plywood under the tank to make sure I didn't damage the hull.

The semi-circle blade does no work very well in corners, so I used the flat blade and the chisel for these areas. Do not underestimate a well sharpened chisel. It easily sliced through the plastic.

[intrlaz]

I had to be more careful on the starboard side because hoses and wires are run past the tank. To avoid any issues (and it actually made the cut easier), I reached out a bit to cut around the difficult areas.

[intrlaz]

After each piece is removed, I continued to slide the tank back toward the stern. Eventually I got to a point where I could maneuver it out of the ski locker.

[intrlaz]

another

[intrlaz]

Reassembled

[intrlaz]

Just to clarify a couple of points.

The after cutting the hole in the top of the tank, I started with cutting a section out of the port side (as seen in the last pic I posted, this is the bottom left section).

The second cut (starboard side opposite of cut 1) is probably the most difficult. If you look inside the tank, you can see area of the rear, starboard side area of the tank is very contoured and would be nearly impossible to get a cutting tool in there. Even if you could, it would be very easy to damage the hoses and wiring behind.

This is why it is easier to reach out further toward the bow and cut around all of this junk. It can be tight, but doing so will save you the hassle of cutting through the contours. See the fourth picture I posted. It is a bit hard to tell since the section is already removed, but you can see how I did not cut straight across and instead reached out.

On another note, I realized before beginning the process that even if I did remove the floor and the gas tank (no small feat), I would still have had to remove the center ballast pump thru-hull (which obviously would have required reinstallation). Just another reason why I am happy with cutting it out.

[RainDog]

Interesting. It is good to know the size and shape of the tank for maintenance and installation issues where you'd be working around the tank. You never stated why you are removing it in the first place. For more storage or are you putting a sac in the locker? Would a sac give substantially more weight than the tank? It looks like the tank fills the available space well.

[intrlaz]

I removed the center tank to make room for a fat sac. Ive read that a full tank would weigh about 300 lbs, where the fat sac can push 580 lbs

[slhesten]

Fat sac vs factory ballast?

Did you ever confirm the weight difference between the full fat sac vs. the factory installed ballast? Is it possible that the fat sac could with 280 lbs more than the factory ballast in the same amount of room?

[seanxtreme3000]

if the front tank weighs 300 what do the 2 back ones weigh. 2003 SANTE
thanks

[jwhposon]

Depends if the two in back are wedges or flat tanks. I know the wedges hold 250 and my center holds 400. I am very curious to know how much he actually can get in the fat sac above the stock ballast because it looked like such a tight fit - or course you wouldn't know that without taking it apart . I am looking at removing my wedge takes and going with 550 sacs on each side in the rear.

2004 sante
Jason Hopson

[brhanley]

I would love to know the answer too. I think the answer is there is approx 30 inches of unused space in front of the tank. Would love confirmation that is true as I may cut out my tank. Thanks so much for the play by play.

[intrlaz]

I was able to measure the capacity of my center sac. It emptied just less than 8 five gallons buckets, so I calculate about 310 pounds. Surely some water was lost during emptying, and I probably could have filled a bit more. Hope this helps.