In Bed Fuel Tanks For Pickup Trucks: Your Ultimate Guide to Extended Range and On-Site Fueling

In Bed Fuel Tanks For Pickup Trucks: Your Ultimate Guide to Extended Range and On-Site Fueling pickup.truckstrend.com

Pickup trucks are the workhorses of the modern world, serving diverse needs from construction sites and farms to off-grid adventures and long-haul towing. While incredibly versatile, they often share a common limitation: the factory fuel tank’s capacity. For those who frequently travel long distances, operate heavy equipment, or venture into remote areas, the need for additional fuel is paramount. This is where in-bed fuel tanks for pickup trucks emerge as an indispensable solution, transforming your truck into a mobile fueling station and significantly enhancing its utility.

An in-bed fuel tank, also known as an auxiliary or transfer tank, is a secondary fuel reservoir designed to be securely mounted within the bed of a pickup truck. Its primary purpose is to carry a substantial amount of extra fuel, typically diesel or gasoline, which can then be transferred to the truck’s main fuel tank or directly to other equipment like generators, tractors, ATVs, or even other vehicles. Far more robust and safer than carrying multiple jerry cans, these tanks offer unparalleled convenience, extended range, and operational efficiency, making them a critical investment for professionals and enthusiasts alike.

In Bed Fuel Tanks For Pickup Trucks: Your Ultimate Guide to Extended Range and On-Site Fueling

Why Choose an In-Bed Fuel Tank? Unlocking Your Truck’s Full Potential

The decision to install an in-bed fuel tank is driven by a range of compelling advantages that address common limitations of standard pickup trucks:

• Extended Driving Range: For cross-country travelers, RVers, or those navigating vast, remote landscapes, an auxiliary tank dramatically increases the distance you can cover between fuel stops. This not only saves time but also provides peace of mind when fuel stations are scarce.
• On-Site Equipment Fueling: Contractors, farmers, landscapers, and anyone operating heavy machinery can significantly boost productivity by having fuel readily available on-site. Instead of repeatedly driving equipment or smaller fuel containers to a gas station, you can refuel directly, reducing downtime and operational costs.
• Cost Savings & Bulk Purchasing: Fuel prices fluctuate. An in-bed tank allows you to purchase fuel in bulk when prices are low, effectively hedging against future price increases. This is particularly beneficial for businesses that consume large volumes of fuel.
• Emergency Preparedness: In the event of power outages, natural disasters, or stranded vehicles, an in-bed fuel tank provides a critical reserve, ensuring you have the necessary fuel to operate generators, transport supplies, or assist others.



• Convenience and Safety: Carrying fuel in approved, securely mounted tanks with proper transfer systems is infinitely safer and more convenient than transporting loose fuel cans, which are prone to spills, odors, and fire hazards.
• Access to Remote Locations: For off-road enthusiasts, hunters, or explorers, an extended fuel supply means deeper penetration into wilderness areas without worrying about running out of gas far from civilization.

Types of In-Bed Fuel Tanks: Finding Your Perfect Match

In-bed fuel tanks come in various configurations, materials, and capacities to suit different needs and truck types. Understanding these distinctions is crucial for making an informed choice:

Materials:

• Aluminum: The most popular choice due to its excellent strength-to-weight ratio, corrosion resistance, and aesthetic appeal. Aluminum tanks are lightweight, durable, and suitable for both diesel and gasoline.
• Steel: Known for its robustness and affordability. Steel tanks are heavier and more susceptible to rust if not properly coated, but they offer superior impact resistance. Often used for larger capacities or heavy-duty applications.



• Polyethylene (Poly): Lightweight, non-corrosive, and often the most economical option. Poly tanks are ideal for DEF (Diesel Exhaust Fluid) and sometimes for diesel, but generally not recommended for gasoline due to permeability concerns and specific regulations.

Designs and Shapes:

• L-Shaped Tanks: Designed to fit over the wheel wells in the truck bed, allowing for some bed space to remain usable. These are popular for their balance of capacity and practicality.
• Rectangular/Square Tanks: Maximize fuel capacity by occupying a larger footprint in the bed, often sitting flush against the cab. Ideal for users whose primary concern is maximum fuel volume.
• Toolbox Combo Tanks: Integrate a fuel tank with a secure storage toolbox, offering dual functionality and saving valuable bed space. These are excellent for tradespeople who need both extra fuel and organized tool storage.
• Low Profile Tanks: Designed to sit below the bed rails, maintaining visibility out the rear window and allowing for tonneau cover installation.

Fuel Transfer Systems:

• Gravity Feed: The simplest and most affordable method. Fuel flows from the higher-mounted auxiliary tank to the lower-mounted main tank via gravity. Transfer rates are slower, and control is less precise.
• 12V Electric Pump System: The most common and convenient method. An electric pump, powered by the truck’s 12V system, rapidly transfers fuel through a hose and nozzle. These systems offer controlled, efficient, and faster fueling.
• Manual Hand Pump: A less common but viable option, especially for smaller tanks or situations where electrical power isn’t desired or available.

Capacity:

In-bed fuel tanks range widely in capacity, typically from 25 gallons to over 100 gallons. Your choice will depend on your specific needs, the frequency of use, and your truck’s payload capacity.

Key Considerations Before Purchase: Making the Right Choice

Selecting the right in-bed fuel tank involves more than just picking a size. Several critical factors must be thoroughly evaluated to ensure safety, legality, and optimal performance:

• Fuel Type Compatibility: This is paramount. Tanks are specifically designed for diesel, gasoline, or DEF. Never use a tank designed for one fuel type for another, especially gasoline in a diesel-specific tank, due to differing material requirements, venting, and safety certifications. Gasoline tanks require stricter venting and flame arrestors.
• Legal Regulations and DOT Compliance: This is perhaps the most crucial consideration. Fuel transfer tanks are subject to strict local, state, and federal regulations, particularly those from the Department of Transportation (DOT) for tanks over a certain capacity (typically 100 gallons for diesel or 119 gallons for gasoline). Ensure any tank you purchase is DOT-compliant if it falls within these categories, or if your application involves commercial use. Regulations cover material, construction, labeling, venting, and mounting. Always research your local laws!
• Truck Payload Capacity: Fuel is heavy (diesel ~7.1 lbs/gallon, gasoline ~6.1 lbs/gallon). A 100-gallon diesel tank, when full, adds over 700 lbs plus the weight of the tank itself. Ensure your truck’s Gross Vehicle Weight Rating (GVWR) and payload capacity can safely handle the full weight of the tank, fuel, and any other cargo.
• Bed Dimensions and Clearance: Measure your truck bed carefully. Consider the length, width, height, and wheel well clearance to ensure the tank fits properly and leaves enough room for other equipment or cargo. Also, check clearance for fifth-wheel hitches if applicable.
• Material and Construction Quality: Look for tanks with robust welds, internal baffles (to prevent fuel sloshing during transit, which can affect handling), secure fittings, and proper pressure relief vents.
• Pump System Specifications: If choosing an electric pump, consider its flow rate (GPM – gallons per minute), hose length, nozzle type, and whether it’s self-priming. Ensure the pump is rated for continuous duty if you plan frequent transfers.
• Mounting and Security: The tank must be securely bolted or strapped to the truck bed to prevent movement during braking, acceleration, or turns. Consider anti-theft measures like locking caps and pump enclosures.
• Ventilation: Proper ventilation is vital for safety. Tanks must be vented to prevent pressure buildup in hot weather or vacuum formation during fuel transfer, both of which can lead to dangerous situations or tank damage.
• Budget: Prices vary significantly based on material, capacity, features (e.g., integrated pump, toolbox), and brand. Factor in not just the tank cost but also any necessary accessories or professional installation.

Installation Guide: Setting Up Your In-Bed Fuel Tank

While professional installation is always recommended for safety and compliance, especially with complex pump systems or large tanks, here’s a general overview of the process:

1. Safety First:

   • Work in a well-ventilated area, away from ignition sources.
   • Disconnect the truck’s battery.
   • Have a fire extinguisher readily available.
   • Wear appropriate PPE (gloves, eye protection).

2. Placement and Positioning:

   • Carefully position the tank in the truck bed, ensuring it’s level and does not obstruct critical components or visibility (especially for low-profile tanks).
   • Allow adequate clearance around the tank for access and air circulation.
   • Ensure it’s not near hot exhaust components.

3. Secure Mounting:

   • Use heavy-duty mounting straps or bolts designed for fuel tanks. Many tanks come with pre-drilled mounting tabs.
   • Drill holes through the truck bed (if necessary) and secure the tank with large washers and lock nuts. Ensure all mounting points are robust and distribute weight evenly.
   • The tank must be completely stable and unable to shift under any driving conditions.

4. Wiring the Pump (for Electric Systems):

   • Run appropriate gauge wiring (usually 10- or 12-gauge) directly from the truck’s battery, through a fused connection, to the pump.
   • Install an inline fuse and a heavy-duty switch in a convenient location (e.g., in the cab or near the pump).
   • Ensure all electrical connections are secure, weather-sealed, and properly insulated to prevent shorts.

5. Grounding:

   • Crucial for safety to prevent static electricity buildup, which can cause sparks.
   • Ensure the tank itself is grounded to the truck frame.
   • When transferring fuel, always ground the receiving tank (e.g., the truck’s main fuel tank or equipment) to the transfer tank before starting the pump.

6. Fuel Line Connections:

   • Attach the fuel hose securely to the pump’s outlet and the nozzle.
   • Ensure all fittings are tightened to manufacturer specifications to prevent leaks. Use thread sealant designed for fuel if recommended.

7. Ventilation Check:

   • Confirm that the tank’s vent system is clear and unobstructed. A clogged vent can cause dangerous pressure buildup or prevent fuel transfer.

8. Testing:

   • Perform a leak check after installation by adding a small amount of fuel and inspecting all connections.
   • Test the pump’s operation.
   • Double-check all mounting hardware after driving a short distance.

Maintenance and Safe Operation Tips

Proper maintenance and adherence to safety protocols are paramount for reliable and safe operation of your in-bed fuel tank:

• Regular Inspections: Periodically check the tank for any signs of corrosion, dents, cracks, or leaks. Inspect hoses, fittings, and the pump for wear and tear.
• Keep Fuel Clean: Use a high-quality fuel filter on your pump system and replace it regularly. Avoid introducing dirt or debris into the tank during fueling.
• Proper Fuel Storage: Do not overfill the tank; leave room for thermal expansion (typically 5-10% of tank volume). Always keep the tank cap securely closed when not in use.
• Grounding During Transfer: Always connect a grounding strap between the transfer tank and the receiving vehicle/equipment before initiating fuel transfer to prevent static discharge.
• Fire Safety: Never smoke or use open flames near the tank during fueling or transfer. Have a fire extinguisher (ABC rated) readily accessible.
• Secure Transport: Always ensure the tank is securely fastened in the truck bed, even when empty.
• Pump Maintenance: Follow the manufacturer’s recommendations for pump maintenance, including checking fluid levels (if applicable) and cleaning filters.
• Venting: Ensure the tank’s vent is always clear and functioning properly.

Potential Challenges & Solutions

While in-bed fuel tanks offer immense benefits, users might encounter a few challenges:

• Legal/Regulatory Compliance:
  • Challenge: Varying state and federal laws regarding fuel transport, especially for gasoline or larger capacities.
  • Solution: Thoroughly research DOT regulations (49 CFR Parts 171-180 for portable tanks/IBCs) and your specific state/local laws before purchase. Choose tanks explicitly certified for your intended fuel type and capacity.
• Payload Overload:
  • Challenge: Exceeding your truck’s GVWR when the tank is full, potentially compromising safety and legality.
  • Solution: Always calculate the total weight (empty tank + full fuel load + pump system + other cargo + passengers) and compare it against your truck’s payload capacity. Opt for a smaller tank or a lighter material (aluminum) if payload is a concern.
• Fuel Sloshing & Vehicle Handling:
  • Challenge: Large volumes of liquid shifting in an unbaffled tank can negatively impact vehicle handling, especially during braking or cornering.
  • Solution: Choose tanks with internal baffles, which compartmentalize the fuel and minimize sloshing. Drive cautiously, especially with a full tank.
• Theft:
  • Challenge: Fuel and transfer equipment can be attractive targets for thieves.
  • Solution: Invest in tanks with locking fuel caps, consider toolbox combo tanks with lockable compartments for the pump and nozzle, and store your truck in secure locations.
• Fuel Contamination:
  • Challenge: Introducing dirt, water, or debris into your fuel system, leading to engine problems.
  • Solution: Always use a high-quality fuel filter on your pump system, ensure the tank cap is sealed, and fill the tank only from reputable fuel sources.
• Installation Complexity:
  • Challenge: Improper installation can lead to leaks, electrical hazards, or insecure mounting.
  • Solution: If you’re not confident in your DIY skills, invest in professional installation. The cost is minor compared to potential hazards or damage.

Representative Price Table for In-Bed Fuel Tanks

Prices for in-bed fuel tanks can vary significantly based on material, capacity, features (e.g., integrated pump, toolbox), and brand. The following table provides representative price ranges as of late 2023/early 2024. Always check current market prices from reputable retailers.

Tank Type/Material	Capacity Range (Gallons)	Key Features	Est. Price Range (USD)	Notes
Aluminum L-Shape	50-100	Lightweight, corrosion-resistant, baffled	$800 – $1,800	Most popular, good balance of capacity & bed space
Aluminum Rectangular	50-150+	Max capacity, heavy-duty, baffled	$900 – $2,500+	For max fuel volume, occupies more bed space
Steel L-Shape/Rectangular	50-100	Durable, impact-resistant, often more affordable	$600 – $1,200	Heavier, good for rugged use, may require rustproofing
Polyethylene (Poly)	50-100	Lightweight, non-corrosive, economical	$400 – $900	Primarily for diesel/DEF, check gasoline compatibility
Toolbox Combo (Aluminum)	50-90	Integrated toolbox, space-saving, baffled	$1,200 – $2,500+	Excellent for trades, higher cost for dual function
Electric Transfer Pump	N/A	12V DC, 8-20 GPM, hose, nozzle, wiring	$200 – $600	Often sold separately or integrated into higher-end tanks
Gravity Feed Kit	N/A	Hoses, valves, fittings	$50 – $150	Simpler, slower, less controlled transfer method

Note: Prices do not typically include installation costs, which can range from $150 to $500+ depending on complexity and location.

Frequently Asked Questions (FAQ)

Q1: Are in-bed fuel tanks legal in all states?
A1: Regulations vary by state and depend on the fuel type (gasoline vs. diesel), capacity, and whether it’s for personal or commercial use. Tanks over specific capacities (e.g., 100 gallons for diesel, 119 gallons for gasoline) often require DOT compliance (49 CFR Part 178). Always check your specific state and local laws.

Q2: Can I carry gasoline in an in-bed tank?
A2: Yes, but tanks designed for gasoline require specific certifications (e.g., UL listed), more stringent venting systems with flame arrestors, and robust construction to safely handle the volatility of gasoline. Never use a diesel-specific tank for gasoline.

Q3: How much weight does an in-bed fuel tank add to my truck?
A3: Calculate the weight of the empty tank plus the weight of the fuel. Diesel weighs approximately 7.1 lbs/gallon, and gasoline weighs about 6.1 lbs/gallon. For example, a 100-gallon aluminum tank (approx. 100-150 lbs empty) full of diesel would add roughly 810-860 lbs to your truck’s payload. Always check your truck’s GVWR and payload capacity.

Q4: Do I need a special license to operate a truck with an in-bed fuel tank?
A4: Generally, for personal use and tanks under DOT thresholds, no special license is required. However, commercial use, especially with larger tanks or hazardous materials, may require a Commercial Driver’s License (CDL) with a hazardous materials endorsement. Consult DOT regulations and your state’s DMV.

Q5: How do I transfer fuel from the in-bed tank to my truck’s main tank?
A5: Most systems use a 12V electric pump that connects to your truck’s battery, drawing fuel from the in-bed tank and dispensing it via a hose and nozzle into your truck’s fill neck. Gravity feed systems are also available, though slower.

Q6: Can I use an in-bed fuel tank for water or other liquids?
A6: No. Fuel tanks are specifically designed and certified for fuel. Using them for water, chemicals, or other liquids can contaminate the tank, damage the pump, or pose safety risks.

Q7: How do I prevent fuel sloshing in the tank?
A7: Choose a tank that incorporates internal baffles. Baffles are compartments or dividers within the tank that break up the liquid’s movement, significantly reducing sloshing and improving vehicle handling.

Conclusion: Fueling Your Freedom and Efficiency

In-bed fuel tanks for pickup trucks are far more than just extra storage; they are strategic investments that redefine your vehicle’s capabilities. Whether you’re a long-haul driver seeking fewer stops, a contractor boosting on-site efficiency, or an adventurer venturing off the beaten path, an auxiliary fuel tank provides unparalleled convenience, cost savings, and peace of mind.

While the benefits are clear, it’s crucial to approach the purchase and installation with diligence. Prioritize safety, thoroughly research legal compliance, and select a tank that perfectly matches your specific needs and truck’s specifications. When chosen and maintained correctly, an in-bed fuel tank transforms your pickup into a self-sufficient powerhouse, ready to tackle any challenge the road, or the lack thereof, throws your way.