What Gap? When a Standard Install Requires a Custom Solution
Turning an Unfinished Gap Into a Factory-Quality Solution
When a department invests in a new fleet of vehicles, the finished product should look professional, function reliably, and feel as though every component belongs there. That expectation can become more difficult when working with civilian-model vehicles. Civilian F-150s offer departments flexibility, but they can also create challenges that are not present in purpose-built police packages. We encountered one of those challenges during the first build in a series of civilian-model F-150s.
When we initially placed the equipment console inside the truck, we immediately noticed a large gap between the console and the surrounding factory trim. The equipment fit, but the installation did not yet have the clean, finished appearance the department deserved. Leaving the gap exposed was not an option.
Putting the Customer's Needs First
With our team's experience in law enforcement, we were able to approach the problem with an understanding of what we would have expected from an upfitter serving our former departments. The solution needed to accomplish two things. It had to create a factory-quality appearance, and it had to be durable and repeatable across every truck in the series.
Instead of simply covering the gap in the first vehicle, we needed to develop a process that could be reproduced consistently in each build that followed.
Our team discussed materials and fabrication methods that had worked on previous projects. We also reviewed the parts and materials available in the shop, including factory components that had been removed from the truck and were no longer going to be used.
That led to an opportunity: repurpose the truck’s original materials to create a solution that looked like it belonged inside the vehicle.
Check out the before and after photos and then finish up the story below!
Testing, Adjusting, and Refining the Process
The first step was cutting away a section of factory trim that would not be reused. Several tools and shaping methods were tested to determine which would produce the cleanest result. The plastic did not respond well to heat. A rotary tool began melting the material, making it difficult to create a consistent finished edge. An oscillating saw ultimately produced a cleaner cut with less heat damage.
The first trim pieces were intentionally cut with extra material, allowing them to be shaped gradually until the fit was right. The process was tedious, but the additional care helped establish a reliable template for the remaining trucks. For the lower sections, we reused carpet that had been removed from the rear wall to accommodate other equipment. The first pieces were carefully shaped, then used to create templates that could be replicated more efficiently on future builds. The upper plastic panels were secured using their original factory tabs. The carpeted sections were attached using an existing factory trim screw and hook-and-loop fasteners placed inside the console.
A Professional Finish That Can Be Repeated
The result was more than a simple filler panel. It was a durable, factory-inspired solution created specifically for the department’s vehicles. By using original materials and factory mounting points whenever possible, the finished installation looked intentional rather than improvised.
More importantly, the process could now be repeated across the rest of the fleet.
That is what thoughtful upfitting looks like. When an unexpected challenge appears, the goal is not merely to make the equipment fit. The goal is to understand what the department needs, develop the right solution, and deliver a finished vehicle that its personnel can be proud to operate.
At HT Upfitting, we do not believe departments should have to choose between functionality and a professional appearance. We work through the details so every build is dependable, repeatable, and built to serve the people who rely on it.