I would not want aluminum tanks. There are very few aluminum tank installations that are proof against corrosion and leakage- especially dangerous with gasoline. Aluminum tanks are hard to check on and are prone to leakage both from inner and outer corrosion. If I had to replace tanks, I would rather get plastic or fiberglass tanks. As to how to recoat a tank: I would saw the top off, clean out the tank, recoat the inside (probably with West epoxy or something like it), then glass the top back on. The HARD part would be taking up the deck and getting the tank out, but if you are in for tank replacements the deck has to come up anyway.
It is worth mentioning here what Tom Slane has done on two 36Cs that he has done over: remove the old Hatteras tanks, take up the deck, and replace the two longitudinal glass tanks with one transverse 375gal tank that is sort of V-shaped on the bottom and sits right aft of the rear bulkhead. Both engines and genset feed from this tank. There are some advantages:
-more fuel capacity
-less trim change as you burn off fuel
-the space aft of the tank can be reconfigured to provide a bigger lift-out fish box which allows very good access to the rudder gear, trim tab pump, etc. It makes a huge difference. Getting under the aft deck of a 36C for maintenance chores is not easy, as any 36C owner knows. This conversion also stiffens the deck as there are fewer hatches cut into it. Note that there is still room for the batteries if you want (where the livewell used to be) and/or storage area.
Tom makes this tank, which makes me wonder if he could make other size tanks as well. I don't know one way or the other, but if you need replacement tanks it would be worth a call to Slane Marine.
