3 hours ago
Aluminum vs Steel for Utility Beds
When outfitting a Chevy 3500 dually for work applications, the choice between aluminum and steel flatbeds is critical. While steel was traditionally favored for its strength, rising material costs and weight penalties have shifted the market. Today, aluminum bodies are often more affordable, lighter, and corrosion-resistant. This weight savings is especially important on one-ton trucks, which can quickly exceed their legal payload limits when loaded with tools, fuel, and equipment.
Terminology Note
A 9-foot flatbed is a common choice for the Chevy 3500 dually, offering enough space for toolboxes, a transfer tank, and equipment without excessive overhang. Aluminum beds from manufacturers like Alum-Line and TruckCraft are popular for their customizability and weight efficiency.
Ideal configuration includes:
Finding toolboxes that fit well and offer sufficient capacity can be challenging. Brands like DeeZee and Weather Guard offer durable aluminum boxes, though some models have been discontinued. When sourcing boxes:
A custom transfer tank that spans the full width of the bed but remains shallow (6–10 inches deep) offers excellent fuel capacity without obstructing visibility or access. Tanks should be:
In Connecticut, operators have successfully outfitted Chevy 3500s with aluminum beds, DeeZee toolboxes, and custom transfer tanks. One setup included a 9' aluminum dump bed with topside boxes and a shallow tank, optimized for landscaping and light excavation. In British Columbia, rising steel prices have made aluminum the default choice, reversing a decades-old trend.
In Georgia, a heavy equipment operator emphasized the importance of overbuilding storage—adding more toolboxes than initially needed. He found that even unused boxes quickly filled with chains, fittings, and spare parts.
Recommendations for Long-Term Use
Outfitting a Chevy 3500 dually with a 9' aluminum flatbed, transfer tank, and toolboxes is a practical and efficient solution for contractors, operators, and fleet managers. With careful planning and quality components, the truck becomes a mobile command center—ready for fueling, hauling, and tool storage on any jobsite. Aluminum builds offer durability, weight savings, and long-term value, especially in regions where payload limits and rust are constant concerns.
When outfitting a Chevy 3500 dually for work applications, the choice between aluminum and steel flatbeds is critical. While steel was traditionally favored for its strength, rising material costs and weight penalties have shifted the market. Today, aluminum bodies are often more affordable, lighter, and corrosion-resistant. This weight savings is especially important on one-ton trucks, which can quickly exceed their legal payload limits when loaded with tools, fuel, and equipment.
Terminology Note
- Flatbed: A platform-style truck body used for hauling equipment, materials, or mounted toolboxes.
- Transfer Tank: A fuel tank mounted on the bed, used to refuel equipment on-site.
- Topside Toolbox: A storage box mounted above the bed rails, often with barn-style doors.
- Underbody Box: A storage compartment mounted beneath the bed, between the wheels.
A 9-foot flatbed is a common choice for the Chevy 3500 dually, offering enough space for toolboxes, a transfer tank, and equipment without excessive overhang. Aluminum beds from manufacturers like Alum-Line and TruckCraft are popular for their customizability and weight efficiency.
Ideal configuration includes:
- One transfer tank across the front of the bed
- Two topside toolboxes (36" barn door style)
- Two underbody boxes for smaller tools and parts
- Mudflaps and stake pockets for added utility
Finding toolboxes that fit well and offer sufficient capacity can be challenging. Brands like DeeZee and Weather Guard offer durable aluminum boxes, though some models have been discontinued. When sourcing boxes:
- Measure bed rail height and width before ordering
- Consider box depth—6" to 10" is ideal for fuel tanks
- Buy in sets if possible to ensure matching dimensions and finishes
- Use rubber isolators to prevent galvanic corrosion between aluminum and steel mounts
A custom transfer tank that spans the full width of the bed but remains shallow (6–10 inches deep) offers excellent fuel capacity without obstructing visibility or access. Tanks should be:
- DOT-approved for diesel or gasoline
- Equipped with a 12V pump and nozzle
- Mounted securely with brackets and vibration dampers
- Positioned to allow toolbox access and hose routing
In Connecticut, operators have successfully outfitted Chevy 3500s with aluminum beds, DeeZee toolboxes, and custom transfer tanks. One setup included a 9' aluminum dump bed with topside boxes and a shallow tank, optimized for landscaping and light excavation. In British Columbia, rising steel prices have made aluminum the default choice, reversing a decades-old trend.
In Georgia, a heavy equipment operator emphasized the importance of overbuilding storage—adding more toolboxes than initially needed. He found that even unused boxes quickly filled with chains, fittings, and spare parts.
Recommendations for Long-Term Use
- Choose aluminum for weight savings and corrosion resistance
- Install more toolboxes than you think you’ll need
- Use custom builders like Alum-Line for tailored solutions
- Maintain clear access to fuel tank fill ports and pump controls
- Keep a log of part numbers and dimensions for future upgrades
Outfitting a Chevy 3500 dually with a 9' aluminum flatbed, transfer tank, and toolboxes is a practical and efficient solution for contractors, operators, and fleet managers. With careful planning and quality components, the truck becomes a mobile command center—ready for fueling, hauling, and tool storage on any jobsite. Aluminum builds offer durability, weight savings, and long-term value, especially in regions where payload limits and rust are constant concerns.
