I’ve been using RotoPax plastic gas cans since I bought my first Jeep. At first they looked cool and were easy to use. When I started to do cross country trips, I started to notice some issues. The fuel cap got harder and harder to remove. It got so bad that nobody in my group was able to remove it. I decided to look for a more reliable solution.
Plastic fuel cans might be durable, but as weather and altitude changes can cause them to become convex or concave, they can be a little scary. On hot days, or when you’re at high altitude, pressure builds and the fuel can bloats (convex). On cold days, pressure drops, and the fuel can walls will start to get pulled in (concave). These pictures were taken in Moab during Easter Jeep Safari 2022. The convex shape happened during the afternoon when the temperature was in the 90’s on a clear day. The concave shape happened in the morning, when the temperature was in the 40s.
There were several concerns with the above scenarios. I was unable to stack two of the 2 gallon RotoPax gas cans, an issue since my goal is to have 4-5 gallons of spare fuel. Without a pressure relief valve, it was difficult if at all possible to remove the cap. I’m not sure if wear and tear over several years made them unusable, but I decided to look for a new gas can solution.
After exploring other options, I decided to return to using a Jerry Can, as we did in the US Army. Wavian is the oldest and most trustworthy brand. 5 gallons of fuel in a metal container, durable enough for the military, and reliable. Unlike cheap knockoffs, the welds are as perfect as you can expect, the inside is treated to be rust proof, and the nozzle design is time tested and tough.
The only issue I found with the Wavian fuel can is the terrible CARB compliant nozzle that they’re required to sell it with. They’re difficult to use and result in fuel spilling all over the place. Luckily usable nozzles are available on Amazon for $29. They’re pretty easy to install and they’re so much easier to use.
The CARB nozzle and the flexible nozzle share the same base, obviously, and they’re both very secure when mounted. The CARB nozzle is a little longer, since it has a convoluted spot that causes fuel to spill, negating any environmental benefits. The flexible nozzle is so easy to use, not a drop was lost when I first tried it. Unlike the spills I had with the CARB nozzle.
To install, you’ve got to remove the existing clamp, and replace it with the new clamp. The old clamp is held in place with rivets. A good pair of diagonal pliers is all you’ll need to remove the rivets holding the old bracket. Once the old bracket is removed, the new bracket takes a few seconds to install with a Phillips screwdriver. Don’t tighten the screws down too much, remember you’re screwing into plastic.
Once the new bracket is on, the new nozzle can be pressed into it. Here are images of the old and new nozzles. They mount onto the can the same way. The flexible nozzle seems to be a little lower profile when it’s in the bracket.
I picked up a Wavian Jerry Can holder for $70. I removed the RotoPax mount from the driver’s side Rock Slide EZ Rack plate that I use to mount my fuel cans and propane gas tank. I went to Home Depot to get five sets of Class 10.9 bolts, nylock nuts, and washers that were as big as could fit in the holder’s recessed holes.
It was easy to put this all together, and wasn’t expensive. The can and mount cost less than a single 2 gallon RotoPax fuel can. The Wavian holder has a padlock hole to keep the can from growing legs. I haven’t figured out how to secure the gas cap so nobody can siphon out my gas. I also need a way to secure the nozzle. I’ll look for a cable lock to take care of that. Oh well, I’ll sort all that out before my August trip to Colorado.
Update 20280325: I just got back from a week long trip to Colorado. The mounted Wavian 20L NATO fuel can worked flawlessly. Very well designed can and mount.
Overlander at large 