AlumiTank Fuel Tank FAQs

Measure the length from weld seam to weld seam — the distance between the two welds at the ends of the tank, not the overall length including the end caps. You'll also want the diameter (for cylindrical tanks) and the location of any fittings. Our measurement worksheet at alumitank.com/worksheets walks you through every step, and there's a short how-to video that shows the process.

Weld-to-weld is the distance between the two end welds of the tank. Overall length includes the end caps, which adds a couple of inches depending on whether the ends are flat or domed. We build to weld-to-weld measurements, so always measure to the welds when ordering.

The most reliable way is to measure your existing tank — weld-to-weld length, diameter, and fitting locations — and match it to your truck's make, model, and year. The year matters for several brands because tank designs changed over time. If you're unsure, our sales team can help confirm the right fit.

We offer two standard finishes: Polished, a mirror-bright exterior, and Milgrade, a durable non-polished mill finish. Polished is available on cylindrical tanks; Milgrade is available across our tank shapes. Custom finishes like powder coating or paint can be quoted as a special request.

For custom tanks, we typically turn around a drawing for your approval within about 24 hours, and production runs about 5–7 business days after you approve the design. Expedited production is available for an additional fee if you're on a tight timeline.

Absolutely — custom work is what we do. We build custom aluminum tanks from 16" to 30" in diameter and up to 90" long (85" for tanks with Peterbilt-style end caps), in fuel, hydraulic, or water configurations. Domed end caps are available in 23" and 26" diameters; other diameters use flat end caps. If you need a diameter, height, or width outside our standard sizes, our sales team can walk you through the custom options available for your application.

All AlumiTank tanks are built from 1/8" 5052 H-32 series aluminum and all of our fittings are made from a 6061 series aluminum. We do not manufacture steel or poly tanks.

No. We manufacture fuel, hydraulic, and water tanks only. We do not make DEF (diesel exhaust fluid) tanks or air tanks.

Most tanks with a 2" 11.5 TPI fill neck come with a fuel cap. Otherwise we don't include a fuel cap — our tanks are designed so you can reuse your original components. We also don't include other parts such as sending units, straps, or brackets unless you request them; those are sold separately from the tank.

Sending units aren't included with a tank, but we sell them separately. Ours are 12-volt and use the standard 240–33 ohm range. We also offer a matching gauge calibrated to that same ohm range.

Baffles are available on request, but they aren't standard and add to the base price of the tank. We don't typically recommend them — in our experience manufacturing fuel tanks, baffles in OEM tanks have broken loose over time and caused internal problems. That said, there are applications where baffling is beneficial, so we're glad to add them when it makes sense for your setup.

Our hydraulic tanks come with a hydraulic fill/breather combo cap that works as both the fill point and the vent, unless you'd prefer a separate breather and filler — in which case the separate vent and cap are sold separately. We don't sell filters, diffusers, or strainers, but they can be installed in our tanks. If you plan to add any of those, let us know up front during the design process so we account for the correct fitting sizes and locations.

A tank's capacity is determined by its diameter and length for cylinder tanks or height, length and width for rectangular or D-shaped tanks. Tell our sales team the gallons you're targeting along with your chassis and we'll recommend dimensions, or measure your existing tank using the measurement worksheets.

We don't supply the heaters themselves, but we can prepare your tank for one. For Arctic Fox and similar heaters, we cut the mounting hole layout (after pressure testing) so you can install your own heater or reuse your existing one. Just let us know at the time of order.

Contact our sales team with the basics: your tank's chassis style, the truck's year, the dimensions, and the finish you want. If you can send a completed measurement worksheet (alumitank.com/worksheets), that's the best way to get the most accurate quote up front. Verbal quotes are subject to change once we create the formal design. Formal quotes — the ones that come with a drawing of the tank design — are good for two weeks from the day they're sent.

Cost varies with the tank's size, shape, finish, and any added options or fittings — for example, baffles or extra fittings add to the base price. For an exact figure, contact our sales team with your specifications.

We accept all major credit cards (subject to a 3% convenience fee) and ACH. You can also apply for a credit account with AlumiTank — contact our sales team for a credit application and they'll walk you through the approval process. Approval times vary depending on how quickly your credit references respond.

All AlumiTank-manufactured products carry a 2-year limited warranty against defects in materials and workmanship, covering the product under normal use and service conditions for two years from the date of purchase (as shown on your invoice). It applies to tanks, steps, brackets, hardware assemblies, and other custom or standard fabrications sold under the AlumiTank brand and invoiced directly by AlumiTank.

The warranty covers the original purchaser only and is non-transferable unless agreed in writing. A valid proof of purchase — your invoice or sales order — must accompany any claim. It does not apply to floor samples or display models, items bought "as is" or second-hand, or products purchased from anyone other than AlumiTank.

The warranty does not cover failures or damage resulting from:

• Improper installation or mounting — for example, support straps placed over a tank's internal baffles, steps bolted contrary to our guidelines, or over-torqued fasteners.
• Unauthorized modifications after delivery — any welding, drilling, cutting, or reshaping without AlumiTank's written approval. If you need extra fittings or features, have us build them in before delivery so the warranty stays intact.
• Misuse, abuse, or extreme operation — over-pressurization, severe off-road use the tank wasn't designed for, or overloading beyond rated capacity.
• Chemical or fuel incompatibility — exposure to corrosive substances or fuels/additives that exceed recommended compatibility limits.
• Normal wear and cosmetic deterioration — scratches, dents, surface corrosion, or finish degradation under typical use.
• Acts of God or external impact — floods, fires, accidents, collisions, or other events beyond AlumiTank's control.

If we manufacture a product based on your own design, drawing, or specification, the warranty covers our workmanship and material quality only. Any design-related flaw or structural inadequacy in a customer-supplied design remains the customer's responsibility.

If AlumiTank confirms a covered defect in materials or workmanship, we'll repair or replace the product (or the affected component) at our discretion, at no cost for parts and labor, and we cover return shipping. Any repaired or replaced item is covered for the remainder of the original warranty period. The warranty doesn't cover incidental or consequential costs such as towing, lost time, or lost fuel, and our responsibility never exceeds the purchase price of the product or its replacement.

Contact us in writing before your warranty period expires — email warranty@alumitank.com with the subject line "WARRANTY CLAIM – [Name / PO# / Invoice# / Serial#]." Include your proof of purchase, clear photos or videos of the defect, and a brief description of how and when you discovered it.

If we determine an inspection is needed, we'll issue a Sales Return Authorization (SRA) number with return instructions. You're responsible for inbound freight unless we specify otherwise.

After inspection, if the defect is covered we repair or replace at no cost for parts and labor and cover return shipping. If it's outside coverage, you can choose to pay for repairs or have the product returned at your expense.