If you’re outfitting a work truck or long-haul setup, aluminum gas tanks deliver lightweight durability and corrosion resistance for fuel transfer needs. This guide focuses on common sizes and configurations that suit gas, diesel, and other liquids, highlighting who benefits most from each option. Below you’ll find five strong choices, each with clear use cases, essential considerations, and simple comparisons to help you decide which tank best fits your truck bed or frame mounting needs.
Summary of top picks (by suitability):
- Best overall for mixed fuels and DOT compliance: 95 Gallon Transfer Refueling Tank
- Best storage plus tank combo: Dee Zee DZ92647 92 Gallon Combo Tank & Toolbox
- Best compact, top-entry design: Aluminum Rectangular Liquid Tank, 45 Gallon
- Best mid-size for auxiliary fueling: RDS MFG Rectangular 69 Gallon Tank
- Best pump-equipped option for quick transfers: 51 Gallon Aluminum Tank Toolbox Combo with 12 GPM Pump
95 Gallon Transfer Refueling Tank
Features include a .125 inch thick aluminum diamond plate and a Special Permit by the U.S. Department of Transportation, making it legally suitable for gas, diesel, methanol, kerosene, aviation fuel, and other liquids. This tank is designed for high-capacity fueling needs and is best for fleet operators who require one sturdy, compliant solution for multiple fuels. It is particularly suited for long-range work trucks or service fleets that transfer fuel on-site or away from stations.
Who it’s best for: contractors, fleet operators, or drivers who need a large-capacity, DOT-legal refueling tank for varied liquids. Why selected: high capacity, legal clearances, and durability with a thick aluminum build. Caution: ensure proper mounting hardware and ventilation when operating near heat sources or ignition sources, as with any large fuel tank.
Dee Zee DZ92647 92 Gallon Aluminum Combo Tank & Toolbox
This option blends a 92-gallon transfer tank with a built-in toolbox, offering convenient, bolted-on storage alongside the tank. The tank features .125 inch Brite-Tread aluminum for durability and an integrated space for tools or gear. Best for users who need a compact fueling solution with on-hand storage for accessories, hoses, or fittings. It is a strong choice for service bodies and work trucks that require on-site fueling plus tool organization.
Who it’s best for: operators needing a dual-function tank and toolbox to maximize space. Why selected: integrated storage reduces loose-tool clutter and keeps fueling gear organized. Caution: weight distribution and mounting should account for the toolbox’s added load, especially on lighter truck frames.
Aluminum Rectangular Liquid Tank, 45 Gallon
This top-entry, upright hydraulic auxiliary or transfer reservoir offers a compact 45-gallon capacity with dimensions around 57 x 9.5 x 20 inches. It is well-suited for trucks that require a smaller, space-efficient tank with straightforward top-entry access for gravity-fed transfers or pump-assisted methods. Best for smaller work trucks or service vans where space is at a premium but a reliable liquid reservoir is needed.
Who it’s best for: owners seeking a compact, top-entry tank with straightforward access. Why selected: favorable footprint for tight truck bed areas. Caution: May have lower capacity for high-volume fueling tasks compared to larger tanks.
RDS MFG Inc Rectangular Auxiliary Fuel Tank – 69 Gallon
RDS MFG’s 69-gallon rectangular auxiliary tank prioritizes durability and straightforward mounting for auxiliary fuel needs. The design is compatible with various truck configurations and is suitable for extended-range operations that don’t require ultra-high capacity. It’s a balanced choice for mid-sized fleets or individual operators on regional routes.
Who it’s best for: operators needing a mid-range capacity tank with reliable construction. Why selected: reliable rectangular form factor and ease of mounting. Caution: verify mounting hardware compatibility with your vehicle’s frame and ensure no interference with spare tires or suspension components.
51 Gallon Aluminum Fuel Transfer Tank Toolbox Combo
This option combines a 51-gallon transfer tank with a toolbox and a 12 GPM, 12V DC pump. It includes a 13-foot hose and auto nozzle, making it a practical all-in-one solution for on-site fueling and quick access to hoses and fittings. Best for smaller fleets or individual operators who value an integrated pump setup for faster transfers and organization.
Who it’s best for: users needing an efficient, pump-assisted transfer setup in a compact package. Why selected: built-in pump and hose system speed transfers and reduce manual handling. Caution: pump performance can be affected by temperature and fuel type; ensure compatibility with your fluids and electrical system.
Buying Guide: Key Considerations For Aluminum Gas Tanks
- Capacity Needs: Choose capacity based on typical fuel consumption, range requirements, and trailer or vehicle payload limits. Larger tanks reduce refueling frequency but add weight and size.
- Material And Construction: Aluminum tanks resist corrosion and are lighter than steel, but thickness and finish (e.g., diamond plate, brite-tread) affect durability and slip resistance.
- Mounting And Fit: Confirm bed or frame mounting options, clearance with tires and suspension, and whether a toolbox or pump is needed in your setup.
- Liquid Compatibility: Verify the fuel types you’ll handle (gasoline, diesel, methanol, kerosene, aviation fuel) and ensure seals and hoses are rated accordingly.
- Compliance And Permits: If DOT or local regulations apply, consider tanks with proper permits or compliance documentation for transport or distribution use.
- Accessories: Pumps, hoses, nozzles, and integrated storage affect convenience and cost. Evaluate whether you need a top-entry design, toolbox, or pump-equipped model.
How To Choose Between Tank Sizes
- For high-volume operational days, a larger tank (70+ gallons) reduces stops and improves throughput.
- For fleets with tight spaces or lighter trucks, a 45–69 gallon model can fit more easily while still meeting daily needs.
- For mixed-use fleets, a combination tank with toolbox supports storage for fittings and helps keep the workspace organized.
Installation And Safety Notes
- Follow manufacturer mounting instructions and use appropriate brackets, bolts, and seals.
- Keep away from heat sources and electrical components; ensure proper ventilation to reduce vapor buildup.
- Regularly inspect for leaks, corroded fittings, and cracked hoses; replace worn components promptly.
FAQ
- What size aluminum tank is best for a typical work truck? A mid-range size (45–69 gallons) often balances capacity with space and weight. For fleets with long routes, consider 70+ gallons.
- Are aluminum tanks safe for diesel and gasoline? Yes, many aluminum tanks are designed to handle multiple fuels and meet DOT or other compliance standards when properly installed.
- Do I need a toolbox with a transfer tank? Not always, but a toolbox improves organization and keeps hoses, filters, and fittings secure while on the road.
- Is a pump-equipped tank worth it? For frequent transfers, a pump can speed operations and reduce manual handling, especially in remote work sites.
- What maintenance is required? Regularly check seals, fittings, hoses, and mounting hardware for wear and leaks; clean exterior surfaces to prevent corrosion buildup.
- Can I install these tanks myself? Basic mounting and plumbing can be DIY with proper tools, but verify warranty terms and local regulations, and consider professional installation for complex systems.