Fleet Upfitting Case Studies 

Explore real-world municipal and commercial fleet builds completed by Trademasters in Chilliwack, BC. These case studies highlight practical, safety-compliant upfits designed to reduce downtime, support repeatable fleet standards, and make approvals simple with clear scope and documentation.

Municipal Case Study - Ford E-Transit

City of Coquitlam — Field Operations Transit Upfit (2025 Ford Transit-350 HD, 148 EXT HiRoof)

Overview

Municipal field crews need a van that functions like a mobile shop: safe storage, fast access to parts, better visibility on-road, and reliable onboard power—without creating clutter or adding inspection headaches. For the City of Coquitlam’s 2025 Ford Transit-350 HD 148" EXT HiRoof, we built a standardized, repeatable interior and exterior spec designed for uptime, organization, and jobsite safety.

The Operational Problem

City crews are constantly moving between yards, streets, and job sites—often carrying mixed equipment, consumables, and paperwork. When a van isn’t purpose-built, the same issues show up quickly:

  • Tools and parts end up stacked or loose, slowing work and increasing damage/loss risk

  • Slippery or unprotected surfaces wear out fast under municipal use

  • Poor jobsite visibility creates safety risk (and compliance exposure)

  • No dedicated power means charging delays, workarounds, and downtime

  • Lifting heavy items into a high-roof van becomes an injury risk and productivity bottleneck

Build Solution

This upfit was designed around four municipal priorities: reduced downtime, jobsite-ready safety, durable organization, and repeatable fleet spec.

1) Interior: Durable protection + organized storage

We started by protecting the van for long service life and easier cleaning:

  • Plywood wall liner kit (Transit 148" EXT HR)

  • Phenolic floor liner kit (high-durability floor protection)

Then we built a storage system that supports fast access and consistent restocking:

  • 72" 4-shelf unit plus a 72" single shelf kit to maximize vertical storage

  • Bin systems for small parts and consumables (multiple bin sets)

  • 36" 3-shelf unit to balance capacity with aisle space

  • A mix of compact drawer units (3-drawer + 5-drawer) for controlled storage of hand tools and sensitive items

  • Multiple in-shelf drawer modules (2-drawer side-by-side and single drawer in-shelf) to keep frequently used items organized at point-of-use

To support paperwork-heavy municipal work, we added a dedicated:

  • Data file box for forms, job sheets, manuals, and documentation

Finally, we created a practical workspace:

  • 72" aluminum workbench top kit and workbench end panel for a durable, easy-clean work surface

Why this matters: crews spend less time searching, less time reloading, and less time dealing with damaged interiors—so they get more done per shift with fewer interruptions.

2) Material handling: safer loading with a van jib crane

Municipal work often involves heavy or awkward items. To reduce strain and speed loading, this build includes a:

  • Van jib crane (400 lb capacity) to lift items from ground level to van floor height and rotate cargo into place

Why this matters: fewer injuries, fewer two-person lifts, faster load/unload cycles—especially in high-roof vans.

3) Exterior safety: beacon + arrow stick for jobsite visibility

Because municipal crews routinely operate roadside, visibility and traffic direction are non-negotiable. We installed:

  • 48" 8-lamp arrow stick + controller + harnes

  • Amber LED beacon (permanent mount)

Why this matters: better roadway presence, safer lane control, and clearer signaling during stops and active work zones.

4) Roof storage: ladder rack + conduit carrier

To keep long materials out of the cabin and free up interior space, we added a full roof solution:

  • WeatherGuard EZ Glide 2 drop-down ladder rack (single side) with mounting brackets

  • Lockable full-length conduit carrier
     

Why this matters: faster access to ladders/long materials, improved interior organization, and a cleaner, safer cabin for operators.

5) Power: 3000W pure-sine inverter + dedicated outlets

Municipal vehicles increasingly need reliable power for devices and tools. This build includes:

  • Samlex NTX 3000W pure sine wave inverter with remote control

  • Auxiliary battery system (Group 27 battery + battery box)

  • DC-DC charger (Orion-Tr Smart 12/12-18A) to support proper charging

  • Blue Sea fuse block for protected distribution

  • 115V outlets installed for practical plug-in access

Why this matters: crews can charge devices, run support equipment, and avoid workarounds that create downtime or electrical risk.

Result: A repeatable municipal fleet spec

The finished van is a division-ready municipal work platform: protected interior, structured storage, a real work surface, safer loading, improved jobsite visibility, and reliable onboard power—built to be repeated across units with consistent layout and parts.

Build Highlights (quick scan)

  • Protective wall liner + phenolic floor for durability

  • Modular shelving + bins + drawer strategy for fast access

  • Data file box for municipal paperwork and documentation

  • Aluminum workbench for daily field tasks

  • 400 lb van jib crane for safer material handling

  • Arrow stick + beacon for roadside safety

  • Drop-down ladder rack + lockable conduit carrier

  • 3000W pure sine inverter + aux battery + fused distribution