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Navatech;
FIrst let me begin by saying I am not trying to rain on your parade. My input is meant only to be another perspective on the choice. I fully respect whatever choice you make....and frankly I'd love to see how the polypro tanks would work out, but forgive me if I say I'd like to find out on on someone else's dime. Maybe you agree with me about that, maybe you don't. But that is your choice to make, not mine.
First:
Wait a minute....
Your stainless steel tanks didn't last 30 years? That begs the question, assuming you are only used them for potable water, as to what sort of stainless they were made from?
Not all stainless is equal, It isn't called "Stain FREE. It is called stain LESS because it WILL rust and stain,.... just less so than mild steel. Some grades rust more than others.
For instance the stuff used for your kitchen knives is 440 and it will rust, but is specified for knives because it takes a better edge. The very best knives are not stainless at all and cannot be left wet on the counter for even several minutes without turning black, much less put through the diswasher; so the 440 SST suits the average home ower's balance of need between dishwasher safe and holding a good edge. But it would suck for fittings or tanks on a boat.It would rust away in a matter of years in a marine environment, particualrly in the lighter gages.
Other rusting stainless grades are used where magnetic properties are important. Macining properties differ and also welding properties differ between the grades. If you want to get a rough idea if you have "rusting" stainess or not see if a kitchen magnet sticks to it. For marine grade stainless the magnet won't stick at all. But in the kitchen grade stainless the magnet usually sticks anywhere from from barely to pretty strongly.
Anyplace in amarine environment you should at minimum use a 316 or a 316L which is a very rust resistant grade of stainless. One suitable for long term use in salt water and marine environments. Nowadays all the better fabricators know how to macine and weld it properly. But of course it costs more than a 440 grade. So if you just say "Make me a stainless steel tank" to a fab house the chances are you are going to get 440 or some variant thereof, not 316.
There are also more exotic grades of stainless even more corrosion resistant, but even more expensive.
As for winterizing; as long as the boat will never go north who cares? Until you want to sell it to someone up north.... Hmmm....
Welding of polypro might not be exotic, but I do not know how welded polypro works as a water tank in a boat. I think that was the point of your original post, i.e. asking if anyone knew anything about this particular application or had first hand experience.
The fact that there seems to be limited to no experience in this application means you are going to be the first to experiment with it if you decide to go that route. Are you prepared to risk the unforseen consequences? It is not just about material strength. It is about other factors from anti freeze compatibility, to vibration, to exposure to bilge fumes, to repeated G loading when in a pounding sea, to mounting questions, to longevity, to resale value, impact resistance, and so on and so forth. And those are the ones I can think of. It is the ones that no one has thought of yet that will bite you the hardest.
In light of these questions what are the specific upsides that you hope to gain by using the welded polypro tanks? What specific properties of the polypro lead you to expect these improvements over the currently used technology? What is your plan if it goes badly? How difficult/ expensive/ inconvenient is it to re-do the project? If you have to undergo a major re-do, is it worth it? What about 1 year in? How about 5 years in? Or 15?
I'm not asking that you answer any of those questions here unless you want to; I'm just saying that this is a way to evaluate your choice.
I am going to be very careful to repeat that I am not trying to critique your choice, whatever it might be. Trust me, I have done enough "from-scratch" designs to know that everyone has a criticism after the design is done, but none of them were helpful when there was only a clean sheet of paper.... and listening to thier reasons why it shouldn't have been done, or how it could have been done better after the fact is not appreciated.
So I am just offering you another way to look at the problem before you make your final decision. Take it for what it is worth.
I wish you the best of luck with whatever you choose. Keep us posted!
Peter
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