How to Carry Extra Fuel on a Suv

Carrying extra fuel on your SUV can be a lifesaver during long road trips, off-grid adventures, or emergencies. This guide covers safe, legal, and practical methods to transport extra gasoline or diesel using approved containers, roof racks, or trailer-mounted tanks—so you’re always prepared without compromising safety.

Key Takeaways

• Use only approved fuel containers: Always choose DOT- or FMCSA-certified gas cans designed for safe fuel transport to prevent leaks, spills, and fire hazards.
• Secure containers properly: Whether inside the cabin or on a roof rack, fuel containers must be tightly fastened to avoid movement during driving.
• Ventilation is critical: Never store fuel in sealed, unventilated areas like trunks or enclosed cargo spaces to reduce vapor buildup and explosion risks.
• Know your vehicle’s weight limits: Extra fuel adds significant weight—typically 6–7 pounds per gallon—so check your SUV’s payload capacity before loading up.
• Follow local and federal regulations: Laws vary by state and country regarding how much fuel you can carry and where; always verify legal limits before traveling.
• Consider alternative solutions: For frequent long-distance or overland travel, invest in auxiliary fuel tanks or trailer-mounted systems for safer, more efficient storage.
• Prioritize safety over convenience: Even small mistakes with fuel handling can lead to serious accidents—always treat extra fuel with respect and caution.

How to Carry Extra Fuel on a SUV

Whether you’re planning a cross-country road trip, heading into remote wilderness, or preparing for emergency situations, knowing how to carry extra fuel on your SUV is a smart and practical skill. Running out of gas in the middle of nowhere—or during a natural disaster when stations are closed—can turn a simple journey into a major headache. Fortunately, with the right tools, knowledge, and safety practices, you can safely transport extra fuel without risking your vehicle, your passengers, or the environment.

In this comprehensive guide, we’ll walk you through everything you need to know about carrying extra fuel on your SUV. You’ll learn about the different types of fuel containers available, how to choose the best storage method for your needs, step-by-step installation instructions, legal considerations, and essential safety tips. By the end, you’ll be confident in your ability to pack extra fuel responsibly and efficiently—so you can focus on enjoying the ride.

Why Carry Extra Fuel?

Before diving into the “how,” let’s talk about the “why.” There are several compelling reasons why SUV owners might want to carry extra fuel:

• Remote Travel: If you’re exploring national parks, deserts, or rural areas with sparse gas stations, extra fuel ensures you won’t get stranded.
• Emergency Preparedness: During hurricanes, wildfires, or power outages, fuel stations may be closed or overcrowded. Having a reserve can keep your vehicle running when it matters most.
• Long Road Trips: On extended drives, especially through regions with limited infrastructure, carrying extra fuel provides peace of mind.
• Overlanding and Off-Roading: Enthusiasts who venture off the beaten path often rely on auxiliary fuel systems to extend their range.

However, it’s important to remember that fuel is highly flammable and potentially dangerous if mishandled. That’s why proper storage, secure mounting, and adherence to safety protocols are non-negotiable.

Types of Fuel Containers for SUVs

Not all gas cans are created equal. When it comes to carrying extra fuel, you need containers that are specifically designed for safe transport. Here are the most common and reliable options:

Portable Gas Cans (Jerry Cans)

Jerry cans are the classic choice for fuel storage. Originally developed during World War II, modern versions are made from high-density polyethylene (HDPE) and feature spill-proof spouts, airtight seals, and built-in handles.

• Capacity: Typically 2, 3, 5, or 10 gallons.
• Pros: Durable, easy to pour, widely available, and often DOT-approved.
• Cons: Can be heavy when full (a 5-gallon can weighs about 35–40 lbs), and stacking multiple cans requires careful securing.

Look for jerry cans labeled as “DOT-compliant” or “FMCSA-approved.” These meet U.S. Department of Transportation and Federal Motor Carrier Safety Administration standards for safe fuel transport.

Flexible Fuel Bladders

Fuel bladders are collapsible containers made from reinforced polymer materials. They’re lightweight and can be stored flat when empty, making them ideal for SUVs with limited space.

• Capacity: Usually 5 to 20 gallons.
• Pros: Space-efficient, easy to store, and resistant to punctures.
• Cons: Harder to pour from, not suitable for long-term storage (can degrade over time), and may not be legal for highway use in some areas.

Always check local regulations before using a fuel bladder, as some states prohibit their use on public roads due to safety concerns.

Auxiliary Fuel Tanks

For serious overlanders or frequent long-haul drivers, auxiliary fuel tanks are a permanent or semi-permanent solution. These are metal or plastic tanks installed in the cargo area, under the vehicle, or in the bed of a truck-style SUV.

• Capacity: 10 to 50+ gallons.
• Pros: Integrated into the vehicle’s fuel system (some models allow direct refueling), highly secure, and reduce the need for frequent stops.
• Cons: Expensive, require professional installation, and add significant weight.

Auxiliary tanks are best suited for diesel SUVs or vehicles used in extreme conditions. Gasoline-compatible models are less common due to volatility concerns.

Trailer-Mounted Fuel Tanks

If you already tow a trailer, consider a trailer-mounted fuel tank. These are standalone units designed to be hitched behind your SUV and filled with gasoline or diesel.

• Capacity: 20 to 100 gallons.
• Pros: Keeps fuel away from the passenger cabin, ideal for long expeditions, and can be locked for security.
• Cons: Requires a trailer hitch, reduces fuel efficiency due to added weight, and may not be street-legal in all jurisdictions.

Always verify weight distribution and braking requirements when towing a fuel-loaded trailer.

Choosing the Right Storage Location

Where you store your extra fuel matters—both for safety and practicality. Here are the most common locations and their pros and cons:

Inside the Cargo Area

Storing fuel inside your SUV’s trunk or cargo space is convenient but comes with risks.

• Pros: Protected from weather, easy access, no modifications needed.
• Cons: Fuel vapors can accumulate in enclosed spaces, increasing fire risk. Also, spilled fuel can damage interior surfaces.

Safety Tip: If you must store fuel inside, use only sealed, approved containers and never leave them in direct sunlight or near heat sources. Crack a window slightly to allow ventilation, and never store fuel in the passenger cabin.

On a Roof Rack

Roof racks offer a secure, external mounting option—especially useful for jerry cans.

• Pros: Keeps fuel away from passengers, frees up interior space, and allows for multiple containers.
• Cons: Adds wind resistance (reducing fuel efficiency), exposes containers to sun and rain, and requires a sturdy rack system.

Use heavy-duty roof racks rated for dynamic loads (while driving). Soft racks or temporary systems are not suitable for fuel containers.

In a Truck Bed or Cargo Drawer

If your SUV has a truck-like bed (e.g., Toyota 4Runner, Ford Bronco), you can mount fuel containers in a locked cargo drawer or bed-mounted bracket.

• Pros: Secure, weather-protected, and out of the passenger area.
• Cons: Requires installation of mounting hardware; not all SUVs have this feature.

Under-Vehicle or Rear-Mounted Systems

Some aftermarket companies offer undercarriage or rear bumper-mounted fuel tanks. These are typically used for diesel and require professional installation.

• Pros: Keeps weight low and centered, improves aerodynamics.
• Cons: Expensive, complex installation, and may affect ground clearance.

Step-by-Step: How to Safely Carry Extra Fuel on Your SUV

Now that you know your options, let’s walk through the process of safely carrying extra fuel. We’ll focus on the most common and practical method: using DOT-approved jerry cans mounted on a roof rack.

Step 1: Choose the Right Containers

Start by purchasing high-quality, certified fuel containers. Look for:

• DOT or FMCSA certification labels
• Spill-proof, self-venting spouts
• Sturdy handles and secure caps
• UV-resistant materials (to prevent degradation)

Avoid cheap, uncertified cans—they’re more likely to leak or fail under pressure.

Step 2: Inspect Your Roof Rack

Ensure your SUV’s roof rack is rated to handle the weight of full fuel containers. Check the manufacturer’s specifications for both static (parked) and dynamic (driving) load limits.

• A typical 5-gallon jerry can weighs ~35–40 lbs when full.
• Two cans = ~70–80 lbs, plus the weight of mounting hardware.

If your rack isn’t strong enough, upgrade to a heavy-duty system like those from Thule, Yakima, or Front Runner.

Step 3: Install Secure Mounting Brackets

Use purpose-built jerry can mounts or universal fuel container brackets. These clamp or bolt onto the roof rails and hold the cans in place.

• Mounts should have rubber padding to prevent scratching.
• Use ratchet straps or locking clamps for extra security.
• Never rely solely on bungee cords—they can loosen over time.

Position the cans so they’re centered and balanced to avoid affecting your SUV’s handling.

Step 4: Load the Fuel Containers

Fill the jerry cans at a gas station using the built-in spout. Never overfill—leave at least 10% air space to allow for expansion.

• Use a funnel to minimize spills.
• Wipe down the outside of the can after filling.
• Label the container with the fuel type (e.g., “UNLEADED” or “DIESEL”).

Once filled, screw the cap on tightly and double-check for leaks.

Step 5: Secure the Containers

Place the cans into the mounting brackets and tighten all clamps or straps. Give each can a firm shake to ensure it doesn’t move.

• Check tightness after the first 10–15 minutes of driving.
• Re-tighten straps periodically, especially on long trips.

Step 6: Drive Safely and Monitor

Extra weight on the roof raises your SUV’s center of gravity, which can affect handling—especially in windy conditions or during sharp turns.

• Reduce speed on highways and avoid sudden maneuvers.
• Be mindful of low-clearance areas (tunnels, drive-thrus, parking garages).
• Check the containers and mounts every few hours during long drives.

Safety Best Practices

Transporting fuel isn’t just about convenience—it’s about responsibility. Follow these safety guidelines to protect yourself and others:

Never Smoke Near Fuel

Gasoline and diesel vapors are highly flammable. Avoid smoking, open flames, or sparks within 20 feet of fuel containers.

Store Fuel Upright

Always keep containers upright to prevent leaks. Never lay jerry cans on their side or upside down.

Avoid Direct Sunlight

Heat causes fuel to expand and can increase pressure inside the container. Store cans in shaded areas when possible.

Use Fume Extractors When Pouring

If your jerry can has a vented spout, use it to prevent splashing and reduce vapor release. Pour slowly and steadily.

Have a Fire Extinguisher Onboard

Keep a Class B fire extinguisher (rated for flammable liquids) in your SUV. Make sure it’s easily accessible and that you know how to use it.

Dispose of Old Fuel Properly

Don’t pour old or contaminated fuel onto the ground. Take it to a hazardous waste facility or auto parts store that accepts used fuel.

Legal Considerations

Laws about carrying extra fuel vary by location. Here’s what you need to know:

• United States: The DOT allows passengers to carry up to 110 gallons of gasoline in approved containers. However, individual states may have stricter rules. For example, California limits portable fuel containers to 5 gallons each and requires them to be DOT-approved.
• Canada: Transport Canada permits up to 110 liters (about 29 gallons) in approved containers. Containers must be securely mounted and not in the passenger compartment.
• Europe: Many countries allow small amounts of fuel in jerry cans, but some require special permits for larger quantities. Always check local regulations before crossing borders.

When in doubt, consult your local Department of Transportation or transportation authority.

Troubleshooting Common Issues

Even with the best preparation, problems can arise. Here’s how to handle common issues:

Fuel Smell Inside the Vehicle

If you notice a gasoline odor inside your SUV:

• Stop driving immediately.
• Check containers for leaks or loose caps.
• Ventilate the cabin by opening windows.
• Inspect the cargo area for spills.

Persistent smells may indicate a cracked container or faulty seal—replace the can immediately.

Containers Rattling or Loose

Vibration can loosen straps over time.

• Pull over at a safe location.
• Re-tighten all mounting hardware.
• Use additional tie-downs if necessary.

Consider upgrading to locking mounts for added security.

Difficulty Pouring Fuel

If fuel won’t flow from the jerry can:

• Check that the vent is open (some cans have a separate vent cap).
• Ensure the spout isn’t clogged.
• Tilt the can slowly to avoid creating a vacuum.

Never force fuel out—this can cause spills or damage the container.

Reduced Fuel Efficiency

Extra weight and roof-mounted containers increase drag.

• Remove containers when not in use.
• Consider switching to a rear-mounted or underbody system for long-term use.
• Maintain proper tire pressure to offset efficiency loss.

Alternative Solutions for Frequent Travelers

If you regularly need extra fuel, consider investing in more advanced systems:

Dual Fuel Systems

Some overland SUVs are equipped with dual fuel tanks—one main and one auxiliary—that feed directly into the engine. These require professional installation but offer seamless refueling.

Fuel Transfer Pumps

Use a 12V electric pump to transfer fuel from a portable tank to your SUV’s main tank. This reduces the need to manually pour and minimizes spill risk.

Solar-Powered Fuel Management

For eco-conscious adventurers, solar-powered pumps and monitoring systems can help manage fuel usage efficiently.

Conclusion

Carrying extra fuel on your SUV doesn’t have to be complicated—or dangerous—if you follow the right steps. By choosing certified containers, securing them properly, and prioritizing safety, you can extend your range and prepare for the unexpected. Whether you’re exploring remote trails or bracing for an emergency, having that extra fuel can make all the difference.

Remember: safety always comes first. Never cut corners when handling flammable liquids, and always stay informed about local laws and best practices. With the knowledge from this guide, you’re now equipped to carry extra fuel confidently, responsibly, and legally.

So pack your bags, fill your tanks, and hit the road—knowing you’re ready for whatever lies ahead.