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Old 04-17-2018, 09:18 PM
mcsurfnj mcsurfnj is offline
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Join Date: Apr 2018
Boat: 1988 ProStar200 w/ 98 evinrude vindicator 200
Location: northeast
Posts: 1
88 prostar 200 fuel tank rot

I've been fixing my uncle's boat that he left for me. He had 5 gallon can hoses hooked up, I eliminated that to begin using the boats tank. I removed the tank to find a nickel size hole rotted through the bottom rear under the fuel outlet. Inside the tank from what I can see looks decent as the metal is shiny. The tank itself is 30 gallons at 48"L x 24"W x 7"H. The below deck section the tank sits in is 25" wide with angled sides.

I have looked for this size tank, only to find similar size tanks, not exact, as well as all of them having a fuel outlet at the top front of the tank. If I were to get a plastic one, what size and would the front fuel outlet matter. I feel like for this boat the fuel tank was purposely designed that way and I shouldn't change it. Do I replace with aluminum or plastic? Can I get this welded and patched? Any input would be appreciated. Thank you
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Last edited by mcsurfnj; 04-17-2018 at 09:21 PM. Reason: add fuel capacity of tank
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Old 04-17-2018, 09:34 PM
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mikeg205 mikeg205 is offline
Join Date: Aug 2011
Boat: 1995 Pro Star 205 5.7 Liter
Location: Plainfield - Joliet, IL
Posts: 17,207
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I would say you're option would be to have a custom one made.
...A bad day water skiing still beats a good day at work...1995 Pro Star 205....
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Old 04-18-2018, 01:47 PM
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orbeamlb orbeamlb is offline
MC Devotee
Join Date: Feb 2012
Boat: 1988 ProStar 200, 1991 Mercury 2.5L 200hp XRi Outboard
Location: Austin, Texas
Posts: 1,165
I see the label is still on your tank. See if the company is still in business. If so, maybe they have a direct replacement. Your PS200 is a 89-91 model, the jet fighter look deck started in 89.
Mike B
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Old 04-27-2018, 06:34 PM
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harborseal harborseal is offline
TT Regular
Join Date: Jan 2015
Boat: 1987 Prostar 190
Location: southeast
Posts: 99
moeller fuel tanks. My old plastic tank , 87 prostar direct drive, has a pinhole leak. Shop won't repair, so having a new one made out of aluminum for $550.00. Tanks this old are ready for replacement. check out the refurbishment thread where there is a lot of information under my handle "Harborseal". suggestions on how to repair are discussed as well as replacement source.
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Old 04-27-2018, 08:03 PM
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harborseal harborseal is offline
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Join Date: Jan 2015
Boat: 1987 Prostar 190
Location: southeast
Posts: 99
titled "gas tank problems 87 prostar".
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Old 04-27-2018, 11:31 PM
Heavanie Heavanie is offline
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Join Date: Mar 2018
Boat: MasterCraft, X10, 2004, restored and modified for salt use
Location: Southeast
Posts: 7
Tank rot

I am in the metal fab and powder coating business and as far as tank rot goes that is bad. Donít bother trying to fix it and donít let anyone tell you it can be. I had that exact boat and had tank issues with it as well. Mine was not a bottom rot issue but a pick up rot problem. In Florida, people like me who will fab tanks are pretty common. I have seen these shipped all over the country. I can give you a quote so you will know approximately what you should be paying if you send me a good sketch. It has been about 20 years since I sold mine. I am now looking for another one so if you ever decide to sell it let me know. Where are you, CT? That first pick looks like the river valley.
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