We repaired our integral water tank a few months ago, here in Uruguay. This video is a recap of the build project from two years ago, and details of the recent repair. Overall, the integral water tank has been a vast improvement. It is easy to clean and fill. We are happy to make use of the space below our cabin sole that was filled with foam. The 65 gallon water tank makes long term cruising much easier.
The bucket sink is versatile and moveable. In Dawn Treader, the first location was below the companionway.
Original sink and galley
Original alcohol stove was below counter hatch
Original location of new bucket sink, alcohol stove removed, Atom stove in place
After altering our companionway and building a new water tank, we got to work on the galley. We created 3 storage sections (where there was one) with watertight bulkheads.
Original hatch size
Resizing opening
Wide open single compartment
Cutting out a little more countertop
Divider bulkhead
Longitudinal divider
Dry fit of bucket sink
Filling holes
Painted!
Nice and clean, ready for hatch covers
Our simple galley design has made its everyday use clean, easy, and fun.
Painted countertop (Interlux Perfection). Open hatch, empty space for bucket
200 hours later, we finished the water tank! Parts 1 (Building an Integral Water Tank) and 2 combined for a rewarding job; now we have double the water capacity (65 gallons), more storage, and an easy to clean cabin sole.
Installing 3 inspection ports
Using an angle grinder to recess the inspection port to stand less proud
Dry fit
Brew coat on the bottom of the sole/tank top
Brew coat (second coat)
Third and last coat
After finishing the brew coat (a food grade epoxy coating), we prepared to epoxy the forward sole section and the main cabin sole/tank top into position. We applied epoxy to the tops of the flange from the old cabin sole, and to the new floors and baffles in the water tank.
Forward sole, to be glued down first
Forward sole section (future storage) with epoxy
Sole/tank top glued in! Filler pieces showing
FIlling/fairing compound
Fairing/sealing tank top in
Aft plumbing for vent and supply
Bilge side plumbing: vent and supply
FInished border paint (interlux epoxy primekote), also cream color interlux perfection with non skid
Yes!
We finished the project by filling and painting the border of our new sole. Our water system works great! Check out our galley post to see our bucket sink, foot pump, and water filter.
Our original project plans did not address changing our water tank. But, upon removing the engine, we gained better access and visibility to the water tank area, this revealed the need for further investigation…
The tank was underneath our cabin sole
We removed a large section to see better
Everything around the tank was super oily!
We cut off the top of the tank
Inside looks ok, but everything else is not
Underneath the tank is oily too
A large bottom panel removed, more oil moisture, and mess
Down the rabbit hole, tank removal continues
After the tank, we move on to removing bucket loads of oily foam in forward areas
Our work continued, and we ended up removing everything from the bilge: water tank, resin blocks, foam (so much foam). We discovered lots of usable storage after removing oily residue, cleaning, and drying out the bilge.
We remained cheerful…
Excavating forward areas
Finding corroded compression post base
Cleaning out this area
Chiseling the resin blocks that surrounded the water tank
Grinding…
After repeat scrubbings, its much cleaner!
Removing the water tank revealed the need for reinforcing the compression post, read more in our related post (Repairing Compression Post Base).
Next, we need to construct a new tank! Our new tank will have an expanded footprint that extends well forward of the previous tank. Also, a new integral tank is a good choice for maximizing our water storage capacity. We hope to double the capacity of the previous tank (from 30 gallons).
Filling flange gap from the old cabin sole
Adding a drain to connect forward bilge to aft bilge
Epoxy for the drain
Fitting new fiberglass pieces to completely line the new tank
Beginning the layup
Continuing, adding peel ply into the night
Complete layup, marking locations for new floors
Fitting new floors
Fiberglassing the flange
Preparing floors for inspection plates
Testing reach from planned inspection plates
Fiberglassing new floors and baffles
Sanded and ready for food-grade epoxy paint and new tank top/sole
Tank top will double as cabin sole. We are ready to have our floor back!
This unexpected project has lots of benefits! We will be able to carry lots more water for long voyages, our hull has been reinforced with 6 new floors and a heavy fiberglass layup, and we now know Dawn Treader is clean from top to bottom! No more hidden treasures!
In part two we complete the tank with paint, install the tank top/sole, add plumbing and inspection ports.