6 Best Auxiliary Fuel Tank Mounts For Long Distance Overland Travel

The vast, sun-scorched stretches between remote gas stations offer a freedom that few other landscapes can provide. However, that same isolation demands a level of fuel security that standard vehicle tanks simply cannot guarantee. Choosing the right mounting system is the difference between a seamless journey and a catastrophic breakdown in the middle of nowhere.

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Rotopax DLX Pack Mount: The Gold Standard

The Rotopax DLX mount has earned its reputation as the industry benchmark for good reason. Its rugged, CNC-machined aluminum construction and oversized tensioning handle allow for a vibration-proof lock that remains reliable even after thousands of miles of washboard roads. When every ounce of gear is subjected to constant jarring, this mount ensures the fuel pack stays exactly where it was placed.

This system is the ideal choice for those who value modularity and minimalism. Because the mount can be bolted to virtually any flat surface, it excels on roof racks, custom storage drawers, or interior cage setups. It is perfect for the overlander who wants a lightweight, low-profile solution that doesn’t scream for attention.

If the goal is versatility and proven longevity, look no further. While it lacks the bulk of heavy-duty steel carriers, its locking mechanism is essentially foolproof. Anyone prioritizing a streamlined build that avoids unnecessary weight should invest here.

Front Runner Jerry Can Holder: For Classic Cans

For traditionalists who prefer the tried-and-true steel jerry can, the Front Runner holder is the definitive solution. Its stainless steel, strap-down design is built to withstand high-impact environments without succumbing to metal fatigue. Unlike proprietary plastic systems, this holder accommodates standard military-style cans found anywhere in the world.

The genius of this design lies in its simplicity and universal compatibility. By utilizing a latching strap and a padded base, it eliminates the metal-on-metal rattling that plagues cheaper alternatives. It is a robust, no-nonsense piece of gear that prioritizes function over form, ensuring the fuel remains secured regardless of the terrain.

This is the best choice for travelers embarking on international trips where sourcing specific plastic packs might be impossible. If the build relies on standard fuel storage that can be swapped out or refilled at any local source, the Front Runner holder is the undisputed winner. It is a workhorse, not a lifestyle accessory.

Expedition One Geri Mount: Most Secure System

Expedition One’s Geri mount stands out for those who worry about fuel theft or accidental dislodging during high-speed trail maneuvers. Featuring a unique locking system that prevents the container from rotating or loosening, it offers a level of security that standard mounts simply lack. It feels substantial, over-engineered, and incredibly solid.

The design is particularly effective for those who mount fuel in exposed, high-vibration areas like external side panels. Because the mount features an integrated locking core, it removes the need for clumsy aftermarket padlocks or cables. It provides peace of mind, knowing the fuel will remain exactly where it was mounted even when the vehicle is left unattended.

Choose this mount if security and extreme retention are the primary concerns. It may be slightly heavier and more complex than a basic knob-style mount, but that investment pays off in durability. It is the perfect match for the serious explorer who traverses deep, isolated wilderness.

AEV Fuel Caddy: Best Tire Carrier Solution

The AEV Fuel Caddy is a masterclass in space-efficient design, utilizing the otherwise dead space behind a full-size spare tire. By contouring specifically to the shape of an AEV rear bumper and carrier system, it keeps the center of gravity low and the profile tight against the vehicle. It is the ultimate solution for those who want extra fuel without sacrificing departure angles or aerodynamics.

This system effectively turns a heavy, bulky spare tire mount into a dual-purpose storage unit. Because it integrates directly into the vehicle’s existing infrastructure, it avoids the common mistake of overloading the roof with top-heavy weight. It feels like an extension of the vehicle rather than an awkward aftermarket add-on.

This product is tailor-made for those who have already invested in an AEV ecosystem. While it lacks the flexibility to be moved to other rigs, its seamless integration is unmatched. For anyone running an AEV rear carrier, this is the only logical fuel-carrying choice.

Prinsu Ridgeline Mounts: The Versatile Choice

Prinsu’s Ridgeline system is designed specifically for those utilizing low-profile roof racks. By integrating into the crossbar extrusions, these mounts provide a streamlined look that minimizes wind drag and noise. It is an exceptionally clean aesthetic for builds that require a sophisticated, modern appearance.

The versatility of the Prinsu mount lies in its adjustment capabilities, allowing for various pack orientations on the roof rack. This adaptability makes it perfect for those carrying multiple fuel packs alongside recovery boards or storage boxes. It turns a crowded roof rack into a highly organized and efficient cargo deck.

This is the right choice for the detail-oriented builder who wants a clean, unobtrusive roof setup. While it demands a specific rack profile, the ease of installation and the ability to rearrange gear makes it highly attractive. If the priority is a professional, integrated look, this system is the clear leader.

Aluminess Swing Arm Carrier: The Integrated System

For the overlander with a full-size van or SUV, the Aluminess swing arm carrier offers a comprehensive solution. This is not just a mount; it is an extension of the vehicle’s frame designed to carry fuel, spare tires, and storage boxes simultaneously. It is built to take a beating, utilizing heavy-duty hinges that handle high static and dynamic loads with ease.

The advantage of a swing arm system is the removal of weight from the vehicle’s roof or internal cargo area. By placing the fuel on a reinforced bumper-mounted arm, the vehicle’s handling characteristics remain predictable during off-road articulation. It is a premium, permanent solution for those living in or traveling long-term out of their vehicles.

This is undoubtedly an expensive, significant investment, but it is necessary for high-weight, high-capacity builds. If the project involves a heavy-duty van or expedition rig, the Aluminess swing arm is the standard for reliability. It is for the explorer who refuses to compromise on capacity or structural integrity.

Where to Mount: Bumper, Roof, or Side Panel?

Deciding where to carry fuel involves a delicate balance between accessibility and vehicle stability. Roof mounting is the most common, but it significantly raises the center of gravity, which negatively impacts cornering and side-slope capability. If roof mounting is chosen, ensure the rack system is rated for the dynamic load of a full fuel pack.

Side panel mounting is an excellent way to keep weight lower, but it often increases the vehicle’s total width. This can be problematic on narrow, overgrown trails where branches or rock faces might snag the fuel pack. Always measure the clearance of the side panels to avoid expensive body damage.

Bumper or swing arm mounting remains the superior option for vehicle dynamics and accessibility. It keeps weight low and centralized, though it does add length to the vehicle’s rear profile. Use this guide to assess the specific needs of the rig:

• Roof: Best for light, infrequently used fuel reserves.
• Side Panel: Ideal for space-constrained, narrow-trail rigs.
• Bumper/Swing Arm: Perfect for heavy-duty, long-distance expedition builds.

How Fuel Weight Impacts Your Rig’s Handling

Fuel is deceptively heavy, with gasoline weighing approximately six pounds per gallon. Carrying five gallons of extra fuel adds thirty pounds of static weight, plus the weight of the canister and the mount itself. When placed high on a vehicle, this weight acts as a lever, significantly increasing body roll and making the vehicle feel top-heavy on uneven terrain.

The most noticeable impact occurs during technical maneuvers, such as steep climbs or off-camber sections. A heavy roof load can cause the vehicle to feel unstable, leading to an increased risk of tipping. Proper weight distribution is essential to maintain the engineered balance of the vehicle’s suspension.

Always calculate the total weight of the fuel system—including the mount—and compare it to the manufacturer’s roof load capacity. If the vehicle feels sluggish or unresponsive, the weight is likely too high or too far back. Shift the weight as low and as close to the rear axle as possible to minimize these negative effects.

Safety & Legal Rules for Carrying Extra Fuel

Transporting volatile liquids requires strict adherence to safety standards and local regulations. Never use containers not specifically rated for fuel; standard plastic jugs are prone to leaking and lack the necessary expansion vents. Always ensure containers are secured upright and away from direct exhaust heat, which can cause pressure buildup and potential ignition.

Legal regulations for fuel transport vary significantly between jurisdictions, especially when crossing international borders. Many regions prohibit external fuel storage that exceeds certain gallon limits or requires specific safety certifications. Failure to comply can result in fines or, in extreme cases, the forced disposal of fuel at border crossings.

Before hitting the road, research the specific transport laws of the destination. Keep an eye on local fire ordinances, as many public lands prohibit certain types of external fuel mounts during high-fire-risk seasons. Safety is not just about the gear; it is about respecting the legal and environmental constraints of the areas being explored.

Pro Tips for a Rattle-Free Trail Installation

Nothing ruins a long drive faster than a constant, rhythmic rattling emanating from the exterior gear. To prevent this, always use rubber isolation washers between the mount and the vehicle’s surface. These small, inexpensive additions absorb high-frequency vibrations that would otherwise loosen bolts and create unwanted noise.

Apply a small amount of thread-locker to every bolt during the initial installation. The constant vibration of off-road driving will inevitably back out loose fasteners, potentially leading to the loss of expensive gear. Regularly inspect the torque on these mounting bolts, especially after the first few hundred miles of rough terrain.

Finally, consider using nylon webbing straps as a secondary safety measure. Even with the most secure locking mount, a backup strap provides a fail-safe that keeps the canister attached to the vehicle if a lock fails. It is a simple, cost-effective habit that ensures the fuel reaches the destination safely.

Proper fuel management is the bedrock of any successful long-distance expedition. By carefully selecting a mounting system that fits the vehicle’s configuration and respects the principles of weight distribution, you can travel with confidence. Invest in high-quality gear, respect safety regulations, and prioritize stability to turn those long, remote stretches into the best parts of the journey.