Update

I've decided on an aluminum tank from Atlantic Coastal Welding because they are responsive and helpful. The plastic tank folks don't seem like they really want to do business.

So, I've prepared the shelf/floor for the new tank. I will use fiberglass tape on the edges and coat the top and bottom of the plywood with at least one coat of epoxy, tab it into the bilge then paint it. Unlike the previous tanks, the new one will NOT be foamed in.

The new tank will be 10 feet long (as opposed to the previous two 5 footers) but I'm still trying to decide whether I want to make it a rectangle or shoehorn an odd shape in for a few extra gallons of capacity.

The old tanks (top) are notched to allow clearance for the fill hose going along the aft tank to the forward tank. The forward tank also needed the notch because the fill fitting requires 2 1/2" of space above the tank for the fill elbo and there's no clearance between the top of the tank and cabin sole. The aft tank fills from the upper part of the tank because it slides about 6" under the bulkhead into the engine room and there's clearance there for the fill fittings. The forward tank is identical except for the placement of the fittings, but is shifted a couple inches to starboard to clear the sink/shower drain pipe going aft to the holding tank.

The original cutaway corner version of the new tank (lower template) fit correctly where the aft tank was, but wouldn't clear the drain plumbing (where the original forward tank had been moved). A rectangle tank would need to be 16.5" wide and 10" tall, whereas an redesigned cutaway corner tank is 18.5" wide and 10" tall...maybe a 15 gallon difference between the two? More to come on the new tank.

I ordered a new bimini for the flybridge 6'L X 4'H X 75"W ($130). The old one (6L X 4H X 5'W) needed a boot and a lot of sewing to get it back in shape. The new one will mount to the rails instead of the sides of the flybridge, giving us a little more rain protection and a better stowage fit when not in use. Pic is of the old one.

Still working on new flybridge upholstery. I bought a commercial back-to-back/lounge setup shortly after acquiring Big Duck and finally got around to slicing the base for a fit on the flybridge, but I think I can do better with a one off custom job incorporating the old bimini hardware.

And before the 2,100 mile trip from SC to Lake Powell this fall, a TPMS will be in/on order for the trailer.