This is the second 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 designing your new forklift, including fabrication, finishing, and assembly.
Introduction: From Design to Manufacture
Turning a drawing into a working forklift is a detailed process that combines precision engineering with hands-on expertise. At Sidetracker, all fabrication and assembly is carried out in-house – using robust materials, skilled teams, and methods refined over more than 60 years.
Every stage contributes to a finished truck that works exactly as your operation requires. Whether it’s a multi-directional forklift for handling awkward loads or a compact model built for tight aisles, each step is carefully planned to ensure maximum strength, safety, and reliability.
What Is a Forklift Truck?
A forklift’s job is simple: lift, move, and position loads. But how it’s made determines how well it can do those things. With the right build, a forklift doesn’t just carry loads – it supports your entire material handling process:
- Manoeuvrability – chassis dimensions and wheel configurations are manufactured to fit your aisle widths and turning spaces.
- Load handling – forks and decks are fabricated to match your loads exactly, reducing wasted aisle space and protecting products.
- Lift performance – masts are built to the precise strength and height needed for clear, safe access to your racking whilst still fitting under and low height restrictions.
- Operator environment – cabs, controls, and onboard systems are specified for comfort, visibility, and efficiency in daily use.
In short, the build of a forklift directly influences how smoothly your operation runs. That’s why every Sidetracker truck is fabricated and assembled to your exact requirements – ensuring the benefits promised in design are fully realised in practice.
1. Fabrication: Creating the Core Structure
Once your custom forklift design drawings are signed off, the first task is to fabricate the core components. These include the chassis, mast, and fork carriage, which must be built to exact requirements before any hydraulics, wiring, or finishing touches are fitted.
Materials Designed to Last
Every Sidetracker forklift begins with heavy-duty steel plate, chosen for its superior strength and stability. For example, 50mm steel leg plates give each truck a low centre of gravity and the durability to withstand demanding conditions. Even if a load is dropped onto its legs, the steel won’t buckle.
By contrast, most other forklifts often break or bend under the same stress. When that happens, the truck may need to be shipped overseas for repair or replacement – a costly and time-consuming process. Our in-house fabrication process avoids this entirely by prioritising long-lasting materials and providing all servicing and maintenance here in the UK.
Cutting and Machining
The raw steel is first cut down to size and then machined to exact specifications. This involves a range of advanced processes, including laser cutting for fine detail, flame cutting for thicker plate, and precision drilling and milling for critical connection points.
Accuracy at this stage is critical. A small deviation at the base of the mast could result in significant misalignment at full lift height. To prevent this, tolerances are kept extremely tight, and components are checked at multiple stages.
Welding and Structural Build
With the materials prepared, Sidetracker’s specialists begin fabricating and welding the core assemblies. The chassis, mast, and fork carriage are each built up from their individual parts, with every piece carefully set into place using cranes and lifting jigs.
The jig work itself is particularly complex. The plates are extremely heavy, and the fixtures must hold the steel in exactly the right position so our welders can achieve the accuracy needed for a structure that stays true under demanding operating conditions.
Once welding is complete, every joint is thoroughly inspected before the components move forward. At this stage, the chassis, mast, and carriage pieces have all taken shape, ready to be painted.
2. Paint and Preparation: Perfecting the Look
After fabrication, the main components are prepared and painted in our dedicated spray booths. Each truck is finished to either Sidetracker’s recognisable orange and grey, or the customer’s chosen colour using a supplied RAL code where required.
The paint process gives the truck its final appearance and ensures the components are fully finished before they’re put together. Once the coating is cured, the parts can be moved into the build area for final assembly.
3. Assembly and Finishing Touches: Making It Yours
Assembly is where the separate components (chassis, mast, and fork carriage) are brought together to form a working truck. It’s also the stage where customer options are built in, so the machine is configured for its exact role.
Chassis and Mast Installation
The assembly process begins with the chassis, where our fitters install drive motors, wheels, valves, switches, sensors, and other core systems. The mast follows shortly after, which can only be mounted once the wheels are in place. Precision at this stage is key, ensuring all systems are adjusted correctly for most efficient use.
Hydraulics and Electrical Systems
Once the mast is secured, the hydraulics can be connected and built up with rollers, hoses, manifolds, chains, and anchors. Care is taken to route hoses to prevent rubbing or damage in use, preventing premature deterioration. With the hydraulics in place, the electrical systems are then installed, supplying the motors and controls. The batteries are then installed.
Bespoke Extras and Finishing Touches
The final stage of assembly is where customer-specific features are added. These may include barcode scanners, weighing systems, cameras, or custom control layouts. Then, with covers, footplates, stickers, and branding in place, the truck is ready for its final checks.
Throughout the build process, we keep you updated on progress so you can plan for delivery. Customers are also welcome to visit the factory during assembly, with the chance to see the truck before testing. Any last-minute adjustments will be accommodated where possible.
Why Customers Trust Sidetracker
A standard forklift might get the job done, but it often means working around limitations – wasted space, awkward load handling, or reduced safety. Sidetracker forklift trucks avoid those compromises by being built to order, in-house.
Customers choose us because we deliver:
- Customisation – every truck is engineered for your individual loads, layouts, and processes, optimising performance, safety, and efficiency.
- Innovation – utilising 60+ years of problem solving experience we are used to coming up with out of the box solutions to your individual handling constraints.
- Sustainability – solar-powered, energy-efficient facilities, plus end-of-life recycling services and eco-truck rebuilds to repurpose used chassis.
- A talented team – with employees who’ve been with us for over 40 years, paired with new talent bringing fresh skills and ideas.
- Continuous development – we’re constantly improving our processes to deliver the best forklifts while maintaining the flexibility Sidetracker is known for.
Coordinating all aspects of fabrication and assembly is a difficult process, but it’s one Sidetracker has mastered. Our expertise and careful planning keep everything running smoothly, allowing us to deliver shorter lead times without compromising quality or performance.
Coming Up in Part 3
In the next post in our How a Forklift Is Made series, we’ll cover what happens after fabrication and assembly, including load, stability, and operational testing, pre-delivery inspections, and after-sales support.
Need help specifying a forklift for your site?
Contact the Sidetracker team to arrange a site visit or talk through your requirements.
FAQs
What is the best forklift brand?
Sidetracker uses a hands-on, manual process refined for over 60 years – rather than a rigid, mass production line. This approach allows us to integrate bespoke features, adjust details as required, and ensure that each truck is tailored precisely to your site and application. That’s why many customers consider Sidetracker among the best forklift manufacturers in the UK.
What is the best narrow aisle forklift?
For narrow aisle operations, space-saving design is essential. Sidetracker’s multi-directional forklifts are built to navigate tight aisles while still handling long or awkward loads. By customising dimensions, load handling attachments, and mast design, we ensure your truck fits your warehouse layout perfectly.
How to make a forklift – what does the process involve?
Making a forklift requires a blend of heavy-duty fabrication, precision machining, and skilled assembly. At Sidetracker, the process begins with steel plate fabrication for the chassis, mast, and fork carriage, followed by painting, fitting core systems, hydraulics, and electrics, and finally adding bespoke extras. This careful approach ensures the finished forklift meets your exact operational requirements.
Who are the best forklift manufacturers?
The “best forklift manufacturers” are those who can deliver a truck that matches your operation exactly. Standard, mass-produced models often mean accepting compromises in space, handling, or safety. Sidetracker takes a different approach – we build every forklift to order.
With over 60 years of experience and specialist expertise in multi-directional forklifts and narrow aisle solutions, we provide a tailored alternative to off-the-shelf brands, ensuring your truck is built around your needs, not the other way around.