Method of making permeation barrier fuel tank

A method of making a permeation barrier fuel tank (10) for a vehicle includes the steps of providing a plurality of layers (30,32,34,36,38). The layers (30,32,34,36,38) include at least an inner layer (30), an outer layer (38), and a fuel permeation barrier layer (34) between the inner layer (30) and the outer layer (38). The method also includes the steps of consolidating the layers (30,32,34,36,38) to form a sheet and thermoforming the sheet into the permeation barrier fuel tank (10).