fill removed, dry core

cutting back core

filled with thickened epoxy

reinstalled

the lab

"Tool" for removing through hull since I didn't have the proper tool on hand. Old junk file to catch on the "ears" inside the through hull and vise grips to hold file.

Original hole for 3/4" through-hull that connects to sink drain, marked for enlarging to fit 1" through-hull.

After enlarging to new size - used Dremel with sanding drum, sanded to pencil line. I taped a plastic bag around the hole on the inside to keep dust out of the boat, and also had a vacuum nozzle taped to the topsides on the outside where I was working.

Dremel with sanding drum used. Pardon the blur but it gives the idea.

New 1" through-hull set in place to check fit - nice and snug.

Temporary/modular water tank setup, overview. Three 6-gallon Reliance brand water jugs - can be found at Wal-Mart, camping shops, etc.

The yellow Starboard™ platform with white cleats was set up for my original water tank, which then sprung a leak. I'm planning to get a new/permanent tank, but in the meantime set up this system. A temporary full width Starboard cleat holds the jugs off the upper/inboard locker side. Three jugs just fit, with storage outboard (behind them).

I had secured Weld Mount footman loops to the cabin sole to strap the "real" tank down to; using them now for holding the jugs in place with the green straps.

The dip tube is a ~2 foot section of 1/2" PVC water pipe. I heated it up with a heat gun and bent it to shape so it would get into the lowest corner of the tanks. It just friction fits into the fitting above it.

I drilled a hole in the cap and fit a nylon elbow into it from above. It's 1/2" barb (hose end) to 1/2" male NPT (end that goes through the cap). That threads into a PVC fitting that is 1/2" female NPT on top, and a meant-to-be-glued socket on the bottom that fits the OD of 1/2" PVC pipe. No need to glue as it's a tight friction fit.

The large ring is the one that comes with the water jug (as is the flat cap I drilled). I just made one of these and can move it from tank to tank. I plan to fill the tanks in place. The hose is the one that runs normally to the foot pump; I just left it extra long when I replaced it. I'll cut it down to size when I put in the new/permanent water tank. More info in "Sunbeam ~ 22 Cruiser" thread.

Decided to add vent hoses since it would be pretty easy and inexpensive. Bought three nylon fittings at the hardware store, 1/4" male NPT to 5/16" hose barb, plus 8' of 5/16" clear hose. Tested friction fit in store - plenty good enough so no hose clamps needed for this setup.

The water jugs had the little white vent fittings that you push into or pull up from the hole. I removed those and used a 3/8" drill bit to enlarge the holes, then put a couple of wraps of Teflon tape around the nylon fitting and screwed it into the jug. Turning tank upside down there was no leakage (there was very slight drippage without the tape). Of course these won't have that much pressure on them when right-side up. Then pushed hose onto barb.

Ran hoses up to currently unused water fill (just to have a place to gather them, nothing to do with the fill in particular), and then with a piece o string tied them in place. The hose compresses slightly so stays there. I also decided to put the jugs into a contractor bag just as a sort of liner in case there are drips when I'm filling or etc.

Vent hoses tied to fill fitting (just to have a place to secure them) (vent is sealed off with expanding plug and thumb screw).

how tank was sitting

resting on hull side, not bottom

view of supply and sight fittings

supply and sight fittings close