EFX, quick question... did you use the sawzall on the tank? I've used one on aluminum plenty of times and don't recall it ever making a spark... but on a fuel tank full of gas fumes, I don't think I'd tank that chance. Obviously you didn't blow up, so that's good!!! I guess I'm just wondering if aluminum will NEVER make a spark with a saw? Plus, sometimes the motors inside power tools make sparks, as well. Just wondering outloud as that's something I've been too worried to try!
Gas tank coffin "sealed"... for what it's worth, my '82 has the same setup as KY's (direct drain, plus a tube running from the cabin bilge). The direct drain is so close to the floor, I'm not sure how well you get a typical rubber plug in there. But again, that's an '82.
BUT... many, MANY boats (stern drives and outboard) have the fuel tank located IN the bilge. Including brand new boats. I can understand the thought process behind why NOT to do that, but it seems there is no ABYC/USCG/whatever to seal the coffin. I suppose a certain manufacturer could CHOOSE to do this, though? There is, however, a requirement for an anti-siphon valve to prevent a hose leak from flooding the bilge (or the fuel line must be run such that it never drops below the top of the tank). Obviously that doesn't tank in account a tank leak.