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MagicMtnDan 05-01-2011 01:41 PM

Build Your Own CO2 Tank System High Quality & Lowest Cost
As an avid off roader I’ve wanted to be able to air down and back up anytime, anywhere and do it quickly but I’ve always been put off by the high price. My goal has been to come up with a solution that is equal to or better than the CO2 tank system suppliers at the lowest possible cost. Here’s what I’ve come up with...

Build Your Own CO2 Air System

On board CO2 tank systems offer incredible convenience to users who can air up tires faster than most any other way even when out in the middle of nowhere. No more hoping a gas station has air or a working compressor and no more buying/carrying air compressors that are costly and take quite a while to air up tires. You can use these at home and use them to power air tools anywhere you take the tank. A 35 x 12.5 tire can be aired up from 5 lbs. to 30 lbs. in under 2 minutes per tire and you can inflate a 35” tire approximately forty (40) times using a 10 pound tank. It’s easy and convenient to refill your tank. CO2 tanks and refills are very common – they’re used in the beverage industry, off roading and paintball as well. Beverage companies and industrial gas companies will refill these tanks. The cost to refill typically is in the $8-$12 range (YMMV). Google “CO2 tank refilling” for more info.

The Good News

You can pick and choose and put together the best, most cost effective system for your needs. If you want a 10# (pound) tank, which is the most common, you can get it. And if, for some reason, you want a 15# or 20# tank, you can buy them too. It’s your choice.

Start with the tank, then choose your regulator with hardware,

Power Tank and Outback Air are the two primary companies involved in selling on board air systems. Tanks are available in different capacities (weights) and the most popular tank size is 10 pounds (which holds 10 pounds of C02). Here are some of the packages these CO2 system companies offer – these are the package prices to beat:

PT10-5200 Basic System with 10lb. tank (“bottle”) is $389.95
And if you want a boot and a mounting bracket the package (PT10-5240) is $439.95

Outback Air
Outback Air XD CO2 System Combo (includes a bracket) is $265.00

Both companies offer 15lb. tanks which are even more costly.

Powertank offers a gauge – shouldn’t the regulator have a gauge? The Powertank regulators typically come with a gauge on the regulator but the truth is no gauges are necessary since tank pressure is constant at ~800 psi when there is liquid CO2 left in the tank (the regulator will read full up until it’s empty). How do you know when to refill? You can measure what's left by weighing the tank. An empty tank with a regulator attached weighs ~15 lbs. and 13 lbs. without the regulator. So a 10lb. air tank and regulator with a fresh charge of liquid CO2 weighs ~25 lbs.

What I’ve come up with is an a la carte solution, a menu that allows us to pick and choose and buy what we want – here are the details:

10# tank shown (above)

These are brand new aluminum tanks with a CGA-320 valve (this is a standard tank and valve – the same as those used by the above industry suppliers). These are brand new aluminum CO2 tanks not reconditioned steel tanks. Every CO2 cylinder is produced from high strength aluminum alloy 6061-T6. These tanks are popular because they are not as heavy as steel tanks and they do not rust. A carrying handle is included on the 10, 15 and 20 lb. cylinders. The service pressure is up to 1800 PSI/124 BAR with a test pressure of 3000 PSI/207 BAR. These cylinders are stamped with required U.S. Department of Transportation and Transport Canada Markings. The 320 Valves are CGA approved, and have a male thread for Co2 Regulators. Note that this supplier is in California so CA residents will be charged tax.

Tanks from call 1-800-710-9939 ask for Jesse Glancy
Be sure to tell him MagicMtnDan sent you and he’ll work to ensure you get the lowest possible cost.

10# tank is 7" diameter x 20.5" high 1800 psi – cost is $86.40

15# tank is 7" diameter x 27" high 1800 psi – cost is $91.15

20# tank is 8" diameter x 27.5" high 1800 psi – cost is $109.20

5# tank (ideal for use in your SxS Rhino, RZR, etc.) $56.00
15# tank shown above


After a lot of Googling, the best regulator solution I have found is from Outback Air. Their regulators are set at 150 psi and besides being an excellent value, they don't have the unnecessary gauges which will read the same up until the tank is empty. Static regulator complete with fitting and automatic quick connect coupler included. Outback Air regulator $55.00

You can order online and the contact there is Tony. You can call him at 1-800-503-0244 and you can email him at Tell him MagicMtnDan sent you.


There are many (many) hose options. I’ve done a lot of searching and contacted some people and here’s what I came up with:

A1 Coupling ( is in Oregon and they claim to provide or have provided hoses and hardware for both Powertank and Outback. I have been working with Dee Evans.

25’ Recoil Air Hose (PURC-14-25R-S-BR-QC) with quick coupler steel, 6-ball and plug steel industrial or automotive style. This is a spiral (coiled) reinforced hose with steel coupler plugs and brass tire chuck. 250 WPSI 4 TO 1 BURST. The hose has reusable fittings with bend restrictors both ends and the hose is reinforced. Available in a variety of colors including red, blue, yellow, and black. Hoses are made in the USA. It’s 1 to 3 days for shipping – most of the time they ship next day. The coupler plugs are steel and they are most of the time because the SS balls in the couplers will pit a brass plug and will be hard to get apart. If you happen to want a brass 6 ball coupler it will cost about $1.00 more. Dee Evans at A1 Coupling thinks most people would use the industrial style couplers. If they want a universal coupler in brass that will work with either one it’s about $2.00 more. The contact is Dee Evans and you can call him with questions and to place orders: 1-541-914-0606. Tell him MagicMtnDan sent you. The price per hose is $20.95 each.

Other hose options:

25’ Coilhose Pneumatics PU14-25B-B 1/4"ID x 25' Blue Flex Coil Hose With 2-1/4" MPT in neon green only $25.00 (from BigJ – he’s on – The Ford Raptor SVT website)

25’ UltraBraid braided straight (not coiled) hose with removable air chuck and coupler assembly $28.95

Reference info & pricing from the “Big Guys” –

Outback Air - 20’ Polyurethane coil hose (not UltraBraid) with removable air chuck is $50.00

Powertank - 25’ SuperFlex Braided High Pressure Coiled Hose HSE-8080 $44.95
25' SuperFlex Braided High Pressure Coiled Hose Our price: $44.95


Deluxe inflator with gauge – 100psi gauge includes rubber gauge guard and storage bag. I recommend using Outback's Deluxe Inflator which enables you to check pressure when inflating so you don't need to switch to a separate pressure gauge and you can let CO2 out if you put in too much pressure.

$55.00 -

There are cheaper solutions – usually kits with a variety of cheap stuff in them – available at Lowes and Home Depot and the auto supply stores. There are also more expensive solutions (see Powertank & others).

Tank Boot

Protects the bottom of your tank and has flat sides to keep tank from rolling when lying down.
$18.69 -

Mounting Brackets

There are many tank brackets available including some designed to mount the tanks to a roll bar (popular in Jeeps).

Powertank offers a variety of brackets

I found a Kidde brand #366424 10lb. Dry Chemical Fire Extinguisher Bracket online for $28.00 A 15# tank bracket can be found here:

Here is a real clever solution that will allow users to mount the tank at an angle still allowing the tank to be used (they should not be used lying down) involving a mounting bracket attached to a piece of bent steel: You can see a number of mounting ideas here:

The Savings

By going with the a la carte purchase plan here’s a package you could put together:

1. 10# tank $86.40
2. Regulator $55.00
3. Hose $20.95

Total cost of the above 3 items is $162.35 - add the $30.00 bracket and the cost is $192.35. Compare this to Outback’s $265.00 combo and you get to save $72.35

The Fine Print

Prices were correct and accurate at time of compilation of information (4/5/11). Prices, as you know, can change at any time. Prices do not include shipping or tax where applicable.

Disclaimer: I did this for myself and figured I’d share it with others who might be interested in being able to air up anytime, anywhere. I am not benefitting in any way from this except, like you, getting the lowest possible cost on a system that I can put together. I am not affiliated with any of these companies.

Let me/us know if you find other products for these systems that you’d like to recommend. This will ensure everyone has access to the latest greatest products. Now go air up!

MagicMtnDan 05-01-2011 01:48 PM

Some relevant CO2 tank threads on

Jerry Bransford 05-01-2011 04:59 PM

Very nice information, thanks. If you don't mind, I will add your information to the FAQ area. I'm currently using a C02 system myself.

MagicMtnDan 05-01-2011 05:09 PM


Originally Posted by Jerry Bransford (Post 11463929)
Very nice information, thanks. If you don't mind, I will add your information to the FAQ area. I'm currently using a C02 system myself.

You're welcome. Please do add the info to the FAQ area.

I've been looking at tank solutions for some time now and haven't pulled the trigger because they're too expensive. I knew there was a better (cheaper) way to go and I'll bet there are still some alternatives out there - like if we can find a less expensive, quality regulator.

I have no dog in this hunt - I just wanted to share my research with fellow offroaders and I hope this is useful to others. :thumbsup:

hoaxci5 05-01-2011 05:18 PM

Watch craigslist for co2 tanks lots of times from home brewers, I've always just swapped tanks instead of having mine refilled, so having a nice new pretty one is just a waste of money. If it's too old it might have to be re-certified but thats a pretty small fee if I remember correctly.

armyRN 05-01-2011 09:50 PM

Thanks for doing the research for us!

thejafe 05-01-2011 10:20 PM

This thread is great ;) . Been wanting to put together a co2 setup for myself for years.

sardog12 05-23-2011 11:25 AM

Here is another thread that some might find useful, especially if they want to mount their tank lying down.

How to use your CO2 tank laying down or standing up

Rubiconcruiser 05-26-2011 10:15 AM

This is an extra for all your CO2 systems, yes it is a great gas however when your are looking for refills paintball stores are a choice, but Nitrogen is a far better choice for product, no moisture in the tires to allow for heating up and expansion, uses also include blowing off the cameera lenses with no issues, CO2 has a tendency to break lenses, the list goes on. Good luck whatever you use.

cheftrail 06-06-2011 07:44 PM

tanks man!

Jerry Bransford 06-07-2011 09:31 AM


Originally Posted by Rubiconcruiser (Post 11607037)
This is an extra for all your CO2 systems, yes it is a great gas however when your are looking for refills paintball stores are a choice, but Nitrogen is a far better choice for product, no moisture in the tires to allow for heating up and expansion,

Surely you're not trying to claim that the C02 our tanks are filled with contains any moisture whatsoever.

Not to mention if you use plain air, that is 80% nitrogen. :)

MagicMtnDan 06-12-2011 08:29 AM

Update to the DIY CO2 System:

Thanks to Zach (aermotor) on another forum for providing a better source for the regulator. Lower cost and flat-rate shipping saves us all about $14.00 more! :2thumbsup:

Regulators – Updated 6/12/11

After a lot of Googling, the best regulator solution for the money that I have found is a fixed pressure regulator which is set at 150 psi. Besides being an excellent value, they don't have the unnecessary gauges which will read the same up until the tank is empty. Static regulator complete with fitting and automatic quick connect coupler included.

The recommended supplier is as they charge $49.00 for their HyperFlo CO2 Regulator plus $7.00 flat-rate shipping ($56.00 to your door). Click this link and scroll down to see the HyperFlo regulator: Thanks to Zach (aermotor) on for this vendor and pricing information!

Note: Previous recommendation was Outback Air ($55.00) but I understand they’re charging $15 shipping for each item!

adamkn 06-19-2011 12:48 PM

Thanks for all the good info!

And thanks for the updated info on the regulator - I was about the buy the one from Outback, but fortunately I checked this page again just before making the order, and I bought the one from Wheeler's instead.

scywin 08-18-2011 07:44 PM

You can do the same thing with any scuba tank, and an old scuba first stage.

I have one of these in my garage for filling tires. Since I am into scuba, the only thing I needed to buy was the adapter.

1911Tyler 09-05-2011 02:52 PM

Great write up. I just ordered a source kit the other day before seeing this. It was 228$ shipped to my door. I thought about building one but it was going to cost about the same but it was much easier to get it all from one place. Mine was 209 plus shipping. It comes with mount, reg, hose, tire chuck, and powder coated bottle. I couldn't beat that.

I hated to give a Toyota company my money but oh well.

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