The fuel fill on my Wahoo! (quite possibly the original) is shot. Actually a lot of the deck hardware could stand replacing, but the fuel fill in particular is cracked and broken. So I bought a replacement. To remove the original, I accessed and removed the hose clamps that secure it to the fuel fill hose via an access port on the port side. Problem is the fuel fill hose is more or less “melded” onto the fuel fill tube. So coming at it from a different direction, I removed the hose clamps that secure the fuel fill hose to the gas tank itself. But again, that hose connection wouldn’t budge, and no amount of twisting, pulling, or prying made any difference.

So it looks like I’m going to have to cut the hose off (using a box cutter or similar device). Which of course will ruin it, although I’m sure it’s  best practice is to replace the hose any time you replace the fuel fill anyway. One last thing I’ll try before cutting is to apply some heat (e.g., wrap the hose in a towel that’s been dipped in boiling water). I’ll report back how that goes.


Added 6/9/12

Well. I finally got the  old fuel fill line off. But it was not easy. In fact it was a bitch. I basically had to saw it off bit by bit with a sharp knife (a box cutter it turned out was too short handled to do the job).  Cutting the hose through the small five inch entry port was hard enough, with me all the while wondering if metal against metal could cause enough spark to ignite fumes from the tank. But then to further complicate things it turned out that A) fuel fill lines include an embedded spiral of wire that you need to cut through, and, B) as my brother-in-law Russ had predicted, the material of the old fuel fill line had more or less melded over time onto the neck coming from the tank: meaning in fact  there was no way I could ever have twisted it off. It had to be cut free. A brute force solution. And man did it fight to maintain that relationship, aided and encouraged by the embedded wire coil, down to the last quarter inch of line. With boats in salt water, nothing is easy. A dremel tool with a cutting wheel probably could have freed the hose in under a minute, but IMO it’d be just too easy to raise sparks or cut too deep.

Lessons Learned: Things I’ll know if and when I next replace a fuel fill:

1. Assume you’ll also have to replace the fuel fill hose, so order that as well.

2. The replacement fuel fill will probably not come with a gasket. So pick up one of those. Also, depending on the shape they’re in, you may want to replace the clamps that secure the fuel fill hose. Inspect everything before ordering your parts.

3. To remove the fill and hose (and assuming that removing the clamps and twisting the hose does not work), cut a vertical slice out of the hose where it covers the neck from the fuel tank. Use a good serrated knife or a small pistol grip saw. Be careful not to cut into the neck. then you can work the hose off. You may also need pliers to pull out pieces of embedded wire you cut exposes.