Axsail
FINDINGS LIBRARY · ENGINE AND FUEL

Fuel tank corrosion: aluminium tanks, foam, pitting and how surveyors write it up

UPDATED 6 NOVEMBER 2026 · 3 EXAMPLE FINDINGS · 2 SOURCES

Why aluminium fuel tanks corrode under foam, straps and bilge water, what a surveyor can and can't see, what replacing a tank involves and three example findings graded A, B and C.

AT A GLANCE
Fuel tank corrosion
USUAL GRADE
A for a leaking tank or fuel in the bilge. B for deep pitting, corrosion where the tank sits in water, or brass fittings on aluminium. C for surface corrosion and a tank that can't be seen
FOUND WITH
Looking at every part of the tank that can be reached, especially the bottom, the straps and the fittings, smelling for fuel, and checking the bilge under it
JUDGED AGAINST
Condition. Good Old Boat's surveyor condemned an aluminium tank that had sat in salt bilge water for 23 years and warned against brass fittings on aluminium
REPAIR COST
About $485 (€420) for a replacement 3/16 inch 5052 aluminium tank in Good Old Boat's account, an older article, plus removal and fitting. Large or buried tanks cost far more

Most fuel tanks sit where nobody looks: under the cockpit sole, behind the engine, sometimes foamed into the hull. An aluminium tank lasts well dry. Hold water against it, in the bilge, under a strap or in foam that's soaked up moisture, and it pits from the outside until it leaks.

How a surveyor checks it

See as much of the tank as you can. The top and the fittings first: corrosion, weeping round the sender and fill, and the fittings themselves. The surveyor in Good Old Boat's account warned never to use brass fittings with aluminium tanks; use stainless.

Then the bottom and supports, where the water collects. That's where Good Old Boat's tank had pitted. Its surveyor condemned it on sight: an aluminium tank sitting in salt bilge water for 23 years means corrosion. Smell for fuel and look in the bilge below.

Foam matters. US rules set limits on how much water foam round a metal tank may absorb, in 33 CFR 183.516, because foam that holds water holds it against the tank.

What decides the grade

Fuel outside the tank is an A. Deep pitting, a tank sitting in water or brass fittings on aluminium is a B. A tank that's mostly hidden, with what's visible in fair order, is a C, and the finding says what couldn't be seen.

Fuel tank corrosion: example findings

The same defect written up at each grade, the way Axsail writes it from what the surveyor says on board. The grade follows what was found, so use these as wording, then grade what you see.

FUELA
Diesel tank, under cockpit sole

Diesel in the bilge below the tank. Tank bottom pitted through at the aft end where it sits on a wet support.

Recommendation: Do not run the engine until the fuel is pumped out and contained. Empty the tank and replace it before the vessel is next used.

FUELB
Aluminium fuel tank

Deep pitting along the tank bottom where it rests in bilge water. Brass fittings on the tank top. No leak found.

Recommendation: Have the tank inspected out of the boat or replaced within 12 months, fit stainless fittings and keep the area under it dry.

FUELC
Fuel tank

Tank mostly hidden under the cockpit sole. Visible top dry with light surface corrosion. No fuel smell.

Recommendation: Monitor the tank and inspect the hidden sides when the sole is next lifted.

ASafety. Safety or compliance deficiency. Fix before the vessel is next underway.
B12 months. Deficiency that needs timely attention. Fix within about 12 months.
CRoutine. Note or observation, cosmetic or maintenance. Routine maintenance at the owner's convenience.

What replacement costs

Job Reported cost
New aluminium tank, small sailboat About $485 (€420), 3/16 inch 5052 alloy, Good Old Boat, older article
Removing the old tank Labour; much more if the sole or a bulkhead must be cut
Fitting, fuel lines and fittings Mechanic's time and stainless fittings
Fuel disposal and cleaning Varies with the fuel aboard

Price is from an older article and will have changed. The labour usually costs more than the tank.

Photos to take

The tank top and fittings, the supports and any visible bottom, pitting close up, and the bilge below. With Axsail, say which parts of the tank you could and couldn't see as you take the photos, and it goes on the fuel finding.

Writing it up

Say what the tank is made of and where it is, how much of it could be seen, the condition of the top, fittings, bottom and supports, and whether there's any fuel outside it. Name any limitation plainly, because a hidden tank is where the next owner's leak starts.

Frequently asked

Why do aluminium fuel tanks corrode?

Water held against the metal. A tank sitting in bilge water, on a wet support, under a strap or in foam that holds moisture corrodes where the water stays. In Good Old Boat's account, the surveyor put it simply, an aluminium tank in salt bilge water for 23 years means corrosion.

Can I see fuel tank corrosion without removing the tank?

Often only part of it. The tank top and fittings are usually reachable; the bottom and the sides against the hull are not. A surveyor reports what was seen and what wasn't, and recommends lifting the sole or removing the tank where there's reason to doubt it.

Why not brass fittings on an aluminium tank?

Brass and aluminium in contact corrode the aluminium. The surveyor in Good Old Boat's account said never use brass fittings with aluminium tanks and to use stainless steel instead.

How much does a new fuel tank cost?

Good Old Boat's author paid about $485 (€420) for a 3/16 inch 5052 aluminium tank with a baffle and clean-out plates, an older figure. Large tanks, and tanks that can only come out by cutting the boat, cost far more in labour than metal.

Your full survey report, minutes after the walk-round

Dictate as you inspect. Axsail builds the findings and the report for your signature

Start free

Standards it's judged against

ABYC H-24

Gasoline (Petrol) Fuel Systems

What ABYC H-24 (gasoline) and H-33 (diesel) cover in a boat's fuel system, which USCG hose types go where, anti-siphon protection, what a surveyor checks and how to cite them in a finding.

What surveyors check
33 CFR 183 SUBPART J

Fuel Systems

What the US federal fuel system rules in 33 CFR 183 subpart J cover on gasoline boats, the hose, anti-siphon, tank and foam rules surveyors check, and how to cite them in a finding.

What surveyors check
ISO 10088

Small craft, Permanently installed fuel systems

What ISO 10088 covers on a CE-marked boat's petrol or diesel fuel system, from the fill to the engine, what it leaves to ISO 21487, what a surveyor checks and how to cite it in a finding.

What surveyors check

Related findings

Findings library
ENGINE AND FUEL

Fuel hose type and age

What USCG Type A1, A2, B1 and B2 fuel hose means, which hose goes where under ABYC H-24 and H-33, what a surveyor looks for, what replacement costs and three example findings graded A, B and C.

How to find and write it up
ENGINE AND FUEL

Missing anti-siphon valve

When a gasoline boat's fuel line needs an anti-siphon valve under 33 CFR 183.568, the alternatives the rule allows, what a surveyor checks and three example findings graded A, B and C.

How to find and write it up
ENGINE AND FUEL

Diesel bug

What diesel bug is, why boat tanks are prone to it, the signs in the filter bowl and on the sea trial, what cleaning a tank costs, what a surveyor checks and three example findings graded A, B and C.

How to find and write it up
ENGINE AND FUEL

Exhaust elbow corrosion

Why marine diesel mixing elbows corrode from the inside, the signs a surveyor looks for, how long they last, what replacement costs and three example findings graded A, B and C.

How to find and write it up
ENGINE AND FUEL

Raw water pump leak

What water from a raw water pump's weep hole means, how impellers fail, what a surveyor checks on the engine's cooling water pump, what a rebuild involves and three example findings graded A, B and C.

How to find and write it up
ENGINE AND FUEL

Failed engine mounts

How to tell when marine engine mounts have failed, from rubber dust to a bracket sitting on the stud, how long they last, what new mounts cost, why alignment follows, and three example findings graded A, B and C.

How to find and write it up

Report templates with this finding

FREE TEMPLATE · WORD

Pre-purchase survey

A free Word template for a yacht pre-purchase survey report: every section explained, example wording, the sea trial and valuation, and example findings graded A, B and C.

Open template
FREE TEMPLATE · WORD

Engine survey

A free Word template for a marine engine survey report: engine records, visual inspection, cold start, readings under load, oil analysis and conclusions, with example findings graded A, B and C.

Open template
FREE TEMPLATE · WORD

Insurance survey

A free Word template for a condition and valuation survey report for boat insurance: each section explained, the insurer's requirements, market and replacement value, and example findings graded A, B and C.

Open template

Related guides

YACHT SURVEYS · 7 MIN

Pre-purchase yacht survey: what it covers, how to book one and what to do with the report

What a pre-purchase boat survey covers, from the haul-out to the sea trial, how to choose a SAMS, NAMS, IIMS or YDSA surveyor, the survey contingency in your offer and how to use the report.