This is the first in our blog series exploring how every Sidetracker forklift is built to order – from first conversation through to delivery and beyond. In this post, we cover what happens after an initial enquiry, including the site survey and design stage.
Introduction: A Forklift Designed for Your Operation
When it comes to material handling, every site is different. That’s why all Sidetracker forklifts are made to order, based on a detailed understanding of your operations. Whether it’s a side loader, multi-directional truck, 4-way reach, order picker, or something more specialist, we work with you to build a solution perfectly tailored to your loads, layout, and processes.
For many customers, the alternative would be buying a standard truck or selecting an off-the-shelf model that’s been designed for someone else with limited customisation. In some cases, it’ll do the job well enough. But if you’re looking to improve efficiency, optimise space, or solve a specific challenge, a purpose-built forklift truck will always do more for your business.
What Is a Forklift Designed to Do?
A forklift is designed to lift, transport, and position loads efficiently and safely. With the right forklift design, you can ensure smooth workflows, protect your product, enhance operator visibility, and make better use of available space – helping you maximise safety, productivity, and revenue.
1. Enquiry: Understanding Your Requirements
It all begins with a conversation. Once you get in touch, you’ll be assigned a dedicated account manager who will talk to you about your objectives. This might be increasing throughput, handling longer loads, operating in confined spaces, or simply improving day-to-day efficiency.
We’ll explore your general requirements, suggest initial model options, and discuss things like lead times, budgets, and any operational constraints. If it sounds like Sidetracker is a good fit, we’ll arrange a site visit at a time that works for you.
2. Site Survey: Built Around Real-World Conditions
The site survey will be carried out by one of our experts. We’ll visit your facility or yard and assess all the practical factors that influence forklift mechanism design, including:
- Aisle widths, turning areas, and clearance heights
- Load sizes, shapes, and weights
- Workflow patterns and traffic routes
- Racking systems and materials storage
- Safety or compliance requirements
- Any operational challenges or opportunities
We’ll also discuss how your team operates and identify any areas where a tailored design could make the job easier – like onboard scanner holders and chargers, visibility enhancements, or custom seating and control layouts.
3. Specification & Quotation
After the site visit, we’ll produce a tailored product specification. This document outlines the recommended Sidetracker model, including all performance criteria (such as lift height, platform width, and capacity), plus any features that will support your team’s work.
You’ll then receive a formal quotation based on this specification. If you’re happy to proceed, we ask for a deposit to confirm your order. From there, the specification moves to our design team, who begin turning it into final forklift design drawings.
4. Initial Design: Engineering to Fit Your Site
Our design team works with advanced CAD tools and design automation software to transform your specification into a production-ready model. We start with one of our trusted forklift templates and adjust each element to match your site and application.
The software allows linked components to update automatically, so if we alter the mast height, for example, the chassis dimensions and weight distribution are recalculated automatically. This ensures every element is in proportion and all parts work together seamlessly.
Unlike some suppliers, we don’t rely on fixed-size components unless they’re genuinely the best fit. If your load is 725mm deep, we build forks, legs and reach to that size – not round up to 1000mm. That gives you better narrower aisles, more control, and safer handling in tight spaces.
Common Forklift Modifications
Every Sidetracker truck is built to order. The options available vary depending on model, but most customers will choose from several key areas of customisation to optimise performance.
Throughout the process, our team will guide you through the options – offering clear, practical advice and only recommending features that will make a genuine difference to your operations.
Vehicle Dimensions & Manoeuvrability
- Compact chassis and reduced desk height for tight or low-clearance spaces
- Full 360° manoeuvrability for precision turning in narrow or high-density spaces
- Choice of three- or four-wheel chassis based on load and stability needs
Fork & Deck Design
- Fork length built exactly to your load sizes for seamless material handling
- No unnecessary fork overhang, which helps reduce aisle width requirements
- Custom deck layout options to handle long, irregular, or bulky items
- Powered extending fork options for double deep racking or unloading vehicles whilst fitting in a narrow aisle
Lift Height & Mast Configuration
- Lift height tailored to your racking and clearance needs
- Balanced mast and chassis designs to maintain visibility and safety
- Strengthened chassis and mast options for high lifts or heavy loads
- 1, 2, 3, 4+ Stage mast designs available
Cab & Operator Environment
- Open or enclosed cabs to suit working conditions or operator preference
- Mirrors, lighting, and access features designed for comfort and control
- Heating, weather protection, and other environment-specific options
Onboard Equipment & Electrical Integration
- Integrated mounts and charging for barcode scanners or tablets
- Optional reversing alarms and beacons for additional safety
- Electrical system integration for accessories, with minimal operator setup
Why a Bespoke Forklift Design from Sidetracker Makes a Difference
A standard forklift might do the job, but it often means working around the truck’s limitations. From space inefficiencies to awkward load handling, those compromises can slow things down, reduce safety, or hold back productivity.
With a bespoke forklift design, you get a truck that’s configured to suit your operation exactly. That means:
- The right dimensions and turning circle for your available space
- A mast height and fork length that match your loads and racking
- Controls, features, and visibility designed for how your team works day to day
It’s about removing the compromises that come with equipment built for someone else. When every detail is specified for your application, you get better performance, improved safety, and a smoother, more efficient working environment.
At Sidetracker, that’s what we focus on. We start with a robust base model, then adapt it to your site, your requirements, and your long-term goals – so the result works the way you need it to, every day.
Coming Up in Part 2
In the next post in our How a Forklift Is Made series, we’ll cover what happens after the final design is signed off – including fabrication, painting, and assembly.
Need help specifying a forklift for your site?
Contact the Sidetracker team to arrange a site visit or talk through your requirements.