I had a similar problem with my starboard FW Tank. Before leaving for weekends I would fill both water tanks. At the end of the weekend both tanks would be close to empty, although I used very little water during the weekend. Both tanks were cross-connected. When I filled the tanks and checked for leaks while on the mooring, both tanks held fine. There way always water in the bilge, but I have a float activated bilge pump, so I never new how much water may have leaked into the bilge.
Anyway, to make a long story short, I found the the starboard water tank had a crack on the top. It held water well when the boat was on the level, but while heeling the tank would leak. I had the tank crack plastic welded and it holds well now.
Now, I never cross-connect the tanks. I'm also very careful while filling the tanks. In the past I would leave the hose in the fill connection until it overflowed. That 4-5 feet of head from the fill connection puts about 2-2.5 psi pressure on the tank, which I believe caused mine to 'explode.' Now I only fill the tanks to the top as viewed from the inspection ports.
Jim Odessey #191
_________________ Jim Voelxen Odyssey #191 Home Port: Osterville, MA
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