What are the safest ways to carry extra fuel and water

Choose certified fuel containers first

Spare fuel belongs in certified containers. Look for markings that show compliance with DOT, EPA, or CARB standards, or a UN rating for transport. Avoid improvised cans and older containers that no longer seal or vent correctly. High density polyethylene and steel both work when built to spec. Steel tolerates heat and impact well, while modern HDPE resists corrosion and is lighter.

Venting and spill prevention

Use containers with reliable caps and proper venting to limit vapor pressure. Inspect gaskets and spouts before every trip. Pack a small spill kit with absorbent pads and nitrile gloves. Never overfill. Allow space for thermal expansion to prevent leaks in hot weather or at elevation.

Mount fuel outside the cabin

Keep fuel outside the passenger area to reduce vapor exposure and fire risk. Use lockable carrier systems that restrain movement in all directions. Avoid roof storage if possible since weight up high reduces stability. If you must use the roof, use tested cradles and confirm that load limits are not exceeded.

Heat and clearance

Maintain clearance from exhaust, heaters, and inverters. Shield from direct sun when parked for long periods. If using a rear door or swing mount, verify it opens fully without stressing the hinge and that lighting and plate visibility remain legal.

Keep water clean, separate, and accessible

Carry drinking water in food grade tanks or jugs that are BPA free and clearly marked for potable use. Opaque or dark containers help reduce algae growth. Separate non potable water for rinsing or shower use so you never mix lines or fittings. Label caps and hoses to match.

Sanitation and treatment

Sanitize tanks and lines on a schedule. Use appropriate dosing of unscented bleach or a camping water treatment, then flush until taste and odor clear. Store hoses dry with sealed ends. For quick trips, sealed jugs simplify hygiene and tracking usage. In freezing conditions, leave expansion room and insulate lines to prevent cracks.

Placement and plumbing

Water is heavy. Place tanks low and centered to protect handling and braking. Use food grade tubing, secure clamps, and strainers before pumps. Include a drain for service, and route a vent line to prevent vacuum collapse while filling.

Manage weight, balance, and legal rules

Weight management keeps a rig predictable. Spread mass evenly left to right, keep heavy items low, and confirm axle ratings. After loading, check tire pressure when cold and adjust to the load chart for your tire size. Reweigh after major changes.

Tie downs and hardware

Use mounts and brackets rated for the full weight of filled containers plus a safety margin. Through bolt to structure with backing plates rather than relying on thin sheet metal. Inspect fasteners after the first rough road and at regular intervals.

Regulations and common sense

Fuel quantity and placement may be restricted in tunnels, ferries, and some public lands. Check posted rules and plan alternate routes when needed. Do not transfer fuel near open flames, pilot lights, or hot engines. Keep a class B or multi class fire extinguisher within reach and know how to use it.

Real world routines that reduce risk

• Pre trip checklist: cap tightness, mounts, straps, and leaks
• Refuel protocol: shut down engine, avoid static, control spills
• Water routine: sanitize cycle, hose care, and dedicated fill points
• Seasonal adjustments: heat, altitude, and freeze protection
• Documentation: keep owner manuals and ratings for your carriers

When to upgrade from temporary solutions

Short trips can get by with sealed jugs and a simple carrier, but longer routes benefit from integrated systems. Fixed water tanks with secure plumbing and dedicated fill ports reduce mess and speed camp setup. Purpose built exterior fuel mounts manage risk better than makeshift racks. If you are unsure about structure, ventilation, or wiring near fuel storage, it is time for professional help.

How OZK Customs builds safety into range and hydration

If you want spare range without sacrificing safety, our team designs exterior fuel storage that respects structure, airflow, and lighting laws. For water, we install food grade tanks, smart fill and venting, and labeled lines that keep drinking water pristine. The result is clean plumbing, solid carrier geometry, and a weight plan that keeps the ride composed. Explore our recreational builds to see how secure storage and thoughtful layout support real travel, not just spec sheets. Visit recreational vans for a look at proven platforms, or step into a tailored plan on custom build a van. If financing a ready platform fits your timeline, see mainstream vans.

Tell us how far you roam between pumps and taps, and we will translate that into safe exterior fuel storage and food grade water systems. We design mounts, plumbing, and power integration that keep your cabin clean, your balance intact, and your trip stress free. Share your trip profile and let us build a system that earns your trust on every mile.

Related pages

• Recreational vans
• Custom build a van
• Mainstream vans