Truck Retrofit Services- Fabrication of Fire Truck to VAC Vehicle
Every service vehicle has a story, and this one began long before it arrived at our Storm’s Welding and Repair shop in Cologne, MN. Our customer purchased a retired fire truck at an auction. The truck was a well-maintained vehicle with plenty of life left in it. But to serve their VAC company’s roadside fleet, it needed far more than a simple tune-up. What started as a decommissioned fire truck was about to undergo a complete vocational truck conversion.
The Customer operates in roadway and municipal environments, providing vacuum (VAC) services such as:
- Strom drain and catch basin cleaning to prevent flooding
- Performing hydro-excavation to safely expose underground utilities
- Maintaining culverts and pipelines
- Handling wastewater and hazardous material removal
- Responding to roadside spills and environmental hazards
For this vehicle specifically, the customer needed:
- A large, open rear platform to carry DOT traffic control equipment and signage (arrow boards, “move over” signs, etc.)
- Durable mounting and storage solutions for vacuum truck operations equipment
- A safe, stable truck capable of operating in high-traffic freeway conditions
Storm’s Welding and Repair Truck Retrofit Services
Initially, this was thought to be a relatively straightforward rebuild by removing the fire equipment, adding a flatbed, and getting it right on the road.
That changed quickly.
Fire trucks are not built like standard commercial trucks. They are essentially constructed as a fully integrated unit from the frame up. This meant Storm’s couldn’t simply “unbolt and remove” components. Instead, they had to systematically dismantle the entire structure.
This project required a comprehensive and methodical approach due to the specialized construction of the original fire truck.
Key challenges:
Complete Structural Disassembly
What looked like a series of compartments and add-ons was actually a tightly integrated structure. The hose boxes, rear firefighter cab, and all fire-specific components had to be removed piece by piece to expose the base chassis for reconstruction.
Electrical System Reconfiguration
Fire trucks pack in complex electrical systems for lights, sirens, and control panels, with routing that rarely translates to everyday commercial use. The team traced each circuit, removed unnecessary components, and reworked the system to ensure the truck functioned reliably for VAC operations.
Heavy Equipment Removal
The fire truck body presented significant weight and structural challenges. Its removal required careful coordination using both a crane and forklift to ensure safe and controlled handling.
Drivetrain Modification
The original pump system integrated directly into the driveshaft; removing it rendered the vehicle inoperable. Storm’s coordinated the design and fabrication of a custom driveshaft, restoring full mobility to the truck.
Mechanical and System Upgrades
Mechanical upgrades included installing reinforced leaf springs, fabricating a custom driveshaft, and performing a full drivetrain inspection to ensure the vehicle could safely carry heavy loads and operate on high-traffic freeways. The air conditioning system also required careful removal, modification, and reinstallation. Storm’s collaborated with a trusted local co-op to complete these specialized mechanical services.
Custom Fabricating a New Work Truck
After the team fully stripped the truck and ensured it was mechanically sound, Storm’s Welding and Repair began the custom truck fabrication phase. All modifications were performed in compliance with DOT safety standards for commercial vehicles. This ensured that the converted truck could safely operate in active roadway conditions and meet municipal fleet requirements.
The team designed and built a custom heavy-duty flatbed tailored to the customer’s operational requirements. We galvanized the flatbed for long-term durability, securely mounted it to the chassis, and fully integrated it with the vehicle’s electrical system.
Wood decking was carefully treated and installed to withstand heavy VAC equipment, while a custom rear bumper hitch was welded and mounted to support additional load-bearing tasks, including transporting arrow boards and move-over signage safely on the highway. Every element of the build was purpose-driven, resulting in a truck configured specifically to support the demands of VAC operations.
A Key Turning Point: Budget and Value
Early in the fabrication process, Storm’s Welding and Repair identified that the scope of the project would be more complex and costly than initially anticipated.
The Storm’s team met with the customer to review the updated scope, budget, and available options. Together, they evaluated whether it was more practical to continue with the rebuild or pursue the purchase of a different vehicle.
After careful consideration, the customer chose to move forward with the rebuild. The reliability of the fire truck drove this decision, as departments typically maintain these vehicles to a high standard throughout their service life. Even with the increased project costs, the rebuild remained a more cost-effective option than purchasing a replacement truck with an unknown history. Additionally, Storm’s Welding and Repair was able to deliver a fully customized solution tailored to the customer’s specific operational needs.
The Final Result: Trusted Service Truck Retrofit Services
Storm’s Welding & Repair was proud to be a part of this project. We custom fabricated this truck to meet the customer’s specific needs and the demands of their daily work.
Astro Metal Craft acquired Storms Welding & Repair in 2023. Storm’s Welding and Manufacturing does custom welding for residential, commercial, and industrial projects. Storm’s also has a strong focus on welding repairs for multiple forms of equipment and industries including trailers, truck accessories, boating, farming and more! At Storm’s we also manufacture our Crowdgate system for diary farmers. At our Storm’s location we sell welding supplies and materials.
For more information visit our Storm’s Welding and Mfg. website or Astro Metal Craft website.
