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SmbWhaler -

When you say it leaks in to the cavity, how are you observing this? Is it strictly through the deck plates? Or have you pulled the deck cover or fuel fill gutter deck cover? If you observe liquid fuel on the top of the tank, it seems more likely that the hoses are at least partly to blame.

When you state that it leaks "when I fill the boat up", is this the only time you notice it (or it is more pronounced then)? After letting the boat sit and for a while, or run after the fill does it seem less noticeable? If so, perhaps you just need to replace the hoses. My impression is that many of those who have needed to replace their tanks have found holes or corrosion on the underside of the tank where the water is more trapped between foam and tank wall. This would likely lead to gas leaking more steadily than just when you fill.

Regardless, you'll probably need to pull the deck for either tank or hose replacement. I found it much easier to replace the hoses with the deck off. I just pulled the deck off of my 1985 Outrage 18 too. It seemed like the tank was still in great shape, I did replace the fill, vent, and outlet hoses, and could certainly see how the vent hose in particular could be subject to wear, as it was compressed by a tank strap.

Dennis