When payload matters, every part of a commercial vehicle needs to earn its place. That is why Charnwood Commercial Bodies continually looks beyond traditional materials and manufacturing methods to find lighter, more practical alternatives.
One example of this approach can be found in the wheel box covers developed for the Aduro low-loader van. Wheel boxes protect the rear wheels where they extend into the vehicle’s load space, but the industry-standard versions were traditionally manufactured from steel. Although strong, steel components add unnecessary weight to a vehicle where every kilogram can affect its carrying capacity.
Working alongside thermoforming specialist Belgrade Polymer Products, Charnwood developed a bespoke composite wheel box cover that is considerably lighter than the conventional steel alternative. The component is manufactured from 6mm ABS, a durable thermoplastic material that will not rust and can be recycled at the end of its useful life.
The development process began with a wooden prototype mould, which was used to produce an initial run of 40 sample wheel boxes. Once the design had been tested and proven, a water-cooled aluminium production tool was created to manufacture future orders consistently and efficiently.
Charley Harris, Charnwood’s Design Engineer, explained the thinking behind the project:
“As our vehicles are weight-driven, using lighter materials is important as they can carry more goods, which appeals to our customers. We try to incorporate composite materials where we can and the wheel box is a great example of this approach.”
Reducing the weight of individual components helps increase the vehicle’s available payload, allowing operators to carry more goods without exceeding the vehicle’s permitted gross weight. A lighter vehicle can also contribute to improved fuel efficiency, making it more economical to operate over its working life.
The project demonstrates how relatively small design changes can make a meaningful difference to the finished vehicle. Rather than simply accepting an established industry solution, Charnwood worked with a specialist manufacturer to create a component tailored specifically to the needs of its lightweight commercial bodies.
This practical approach to design remains central to Charnwood’s work. By carefully considering the materials, construction and purpose of every component, the team can produce commercial vehicle bodies that maximise payload while remaining strong, durable and suited to everyday business use.