Custom Fuel Tanks

Diesel Fuel & Hydraulic Oil

Please feel free to download our tank design guide which will assist you in providing us with all the information we need to build your plastic custom diesel  tank.

  Tank Design Guide
Fittings Guide


Better By Design

Heavily corroded galvanised mild steel tank

Heavily corroded galvanised mild steel tank

Over the past two decades, TEK-TANKS designers and engineers have developed a plastic tank construction system using high strength, advanced polyethylene materials that overcome the persistent corrosion and weight problems of mild steel and the mechanical failure of flexible bag style tanks. Over 40% of our current work is building replacement plastic tanks for boats previously fitted with mechanically unreliable flexible bags or stainless and aluminium tanks with electrolysis problems.

Less Condensation

The particular specification of polyethylene which TEK-TANKS uses will help with the problem of water condensation inside the fuel tank. Although not totally eliminating it, the material heat transfer properties greatly reduce the amount of water condensing out in the airspace left. It is always advisable where possible to leave the plastic diesel tanks nearly full when left for any length of time.

Computer Aided Design and Manufacture





After being computer designed on our CAD system, components for each plastic diesel tank are cut to exact shape and size on our CNC Router. These panels are then fitted together and welded in place using the latest hot gas extrusion welding systems.



Pressure Testing For Reliability

As part of our commitment to quality and reliability, every TEK-TANK tank, (built from 10 – 12 mm Polyethylene), is pressure tested to 4 p.s.i. ( 8′ hydraulic head).


Tank BafflesBaffles For Strength And Security

TEK-TANKS standard specification includes baffles placed approximate every 300 mm. On larger plastic diesel tanks these are locked into position by means of an interlocking pin and ribs situated under the top panel. This design feature prevents the top of the tank from lifting when under pressure.

These carefully planned internal baffles also perform two additional important functions. Firstly, they introduce immense rigidity to the design of the plastic diesel tank, and secondly, they cleverly limit the dynamic movement of contents, thus minimising the destructive pounding forces against the tank body.

Custom Fuel TanksInspection Hatches

The Tek-Tanks standard fuel hatch is 200mm OD with 18 x M8 bolts which protrude above the tank top by 25mm. A high quality 3mm thick nitrile gasket is used between the tank top and the underside of the hatch. Where height is an issue a low profile version is available giving a total height of 15mm. A larger 270mm OD hatch is available. Where cross baffles are adjacent to an inspection hatch, the baffles have on average, eight inch diameter cut-outs to facilitate cleaning and maintenance.


The fittings on all bespoke plastic diesel tanks are all marine grade brass. Feeds and take-offs are normally a banjo fitting supplied as standard with a nut and olive to accept copper pipe. Hose tails are available to connect to flexible hose. Please specify when ordering which type of pipe/hose is being used.

Custom Design And Production

Bespoke plastic diesel tanks built from rigid polyethylene lend themselves to one-off production because there are no expensive mould tools to build. Custom plastic diesel tanks are of all welded construction and built to the customers own design, but to TEK-TANKS demanding and proven specifications. Polyethylene cannot be easily curved, but multifaceted shapes normally solve most design problems. Please bear in mind when designing your tank that the more complicated the shape, the more expensive the tank.

Trade Customers

TEK-TANKS offers the custom and production boat builder the ideal solution to providing plastic tanks for storing diesel fuel. Tek-Tanks are unable to manufacture custom built plastic tanks for petrol, but we can supply a large range of standard moulded tanks which are manufactured using the blow moulding process. We will be pleased to help with any design problems and offer a fast and efficient service from our workshop in Upper Froyle near Alton in Hampshire.

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