88' Broward Superyacht
Fuel Tank Replacement
Full integral tank removal and replacement — ABS-certified, 3-week turnaround
Project Overview
An 88-foot Broward motoryacht arrived with failing integral aluminum fuel tanks — a common failure point on vessels of this vintage. The tanks had corroded at the seams, and the captain needed the boat back in service before a Caribbean charter season. DolFab fabricated and installed a complete replacement tank system in under three weeks, earning ABS sign-off on the first survey.
The Challenge
The original tanks were structurally integrated into the hull — not drop-in units. Removal required cutting into interior spaces without damaging surrounding systems. New tanks had to match the exact geometry of the originals, satisfy ABYC H-33 and USCG standards, and be fabricated to ABS classification requirements. The owner had 21 days before the vessel had to ship to Nassau.
The Solution
DolFab templated every dimension in-situ before touching the originals. Replacement tanks were cut from 5052-H32 marine aluminum plate, TIG-welded with full-penetration seams, and pressure-tested to 3 PSI before installation. All penetrations, pickups, and vents were positioned to match the OEM layout exactly. The ABS surveyor signed off without a single punchlist item — vessel departed on schedule.
Project Timeline
On-vessel templating of original tanks. Documentation of all fittings, pickups, vents, and structural attachment points. Material order placed same day.
Tank panels CNC-cut from 5052-H32 plate. TIG welded with full-penetration seams. All fittings installed and pressure-tested at 3 PSI for 24 hours.
Original tanks surgically removed. Hull surfaces cleaned and inspected. New tanks set, secured to original mounting structure, and all plumbing reconnected.
System pressure and leak tested at dock. ABS surveyor inspection — zero punchlist items. Vessel departed for Nassau on Day 21 as scheduled.
Project Details
- Vessel
- 88' Broward Motoryacht
- Material
- 5052-H32 Marine Aluminum
- Process
- TIG Welding, CNC Cutting
- Scope
- Full Integral Tank Replacement
- Standard
- ABYC H-33, USCG, ABS
- Timeline
- 3 Weeks Start to Completion
- Location
- Fort Lauderdale, FL
- Certification
- ABS Sign-Off, First Inspection
"Tank was out, new one in, and we were fueled and underway in three weeks flat. ABS surveyor didn't find a single thing wrong. These guys are the real deal for superyacht work in Fort Lauderdale."
Need Fuel Tanks Replaced?
Integral or drop-in, aluminum or stainless — we template, fabricate, and install. ABS certification available. Most jobs complete in 2–4 weeks.