Need design idea. . .Ammo Gas Can

I want to convert a military surplus ammo can into an extended gas tank.

I see 2 ways of doing this. Either putting a 1 gal gas tank into it and use it as a cover, OR make the whole can as a fuel reserve.

Either way I want to keep the lid intact. Not sure if the stock seals are fuel resistant or not. Not sure how to test either without just soaking one in gas.

If the seals are gas resistant that would be perfect, just drill holes for the line to the carb and fit a T to the stock gas tank line, with a petcock below it going into the carb.

Anyone have experience with this, either working or failed?

That gas tank repair stuff looks like it might fit the ticket.

What I am considering is making an metal "z shaped" inner lid to contain the gas. Reason for the shape is so I can attach a gas cap to the inner piece.

Something like this, with the gas cap welded into the lower section. Then use the gas tank sealer to make a lip that the lid sits on and once cured make a seal on the top side.


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I have 2 sizes of ammo boxes right now. the large one has an inner size of 668.9 cubic inches, the smaller is 423.5. If I did the math right that is 2.89 and 1.83 gallons minus the space taken up by the inner lid. Can't decide what size to go with lol.

Around town and maybe to the next town over, which is only 30 miles. I just like the idea of not having to fill my 1 gallon gas can every 5-8 days.

Problem is, if I mount the ammo can on the rack then I use up my crate space I use to haul tools.

I'm considering a half and half solution. Turn the back half of the ammo can into a gas tank, and the front half for tool storage. Probably go with a drop-in gas tank.

If the seal is good, I know they can be water tight, but I haven't found anything that makes me believe they are gas proof.

I considered the ammo cans as saddle bags, but don't know if I want the weight of 3 ammo cans on my bike plus weight of the fuel plus all the gear I could put in the 2 smaller ammo cans.

If I could split the larger one into 2 compartments, half for gas other for tools, I think that would be the best of both worlds.