One-size-fits-all traffic control trucks waste money, fail inspections, and leave workers exposed. A mismatched TMA or arrow board can trigger $50,000 Caltrans fines or, worse, a preventable rear-end collision. Western Highways Traffic Safety has custom-built over 420 shadow vehicles since 2008—each engineered to the exact project, fleet, and agency requirements. Our in-house fabrication, wiring, and certification teams deliver MASH-compliant trucks that pass inspection 100% of the time. This guide shows six ways we customize trucks to fit your specific needs. Call (559) 785-1400 or email info@westernhighwaystrafficsafety.com to spec your next vehicle today.
Off-the-shelf trucks rarely meet California’s unique demands: high-speed freeways, mountain grades, coastal winds, and strict Caltrans lighting rules. Western Highways starts every build with a detailed needs assessment—then fabricates, wires, and certifies the truck in-house. A Central Valley paving contractor saved $38,000 in rework after our custom TMA truck eliminated underride risks on 70 mph zones. These six customization strategies ensure your truck works perfectly for your jobs.
Strategy 1: Exact TMA Selection and Host Vehicle Matching
Requirement: MASH TL-3 demands 26,000+ lb GVWR for 70 mph protection. Our Process: Match Scorpion II, Verdek VPS, or Trinity attenuators to your truck class—10,000 lb pickups get TL-2 100-series; Class 8 semis get 350-series heavy haulers. Customization: Ballast boxes, extended frames, or hydraulic lift gates for low-clearance bridges. Result: A Stockton contractor’s 33,000 lb Kenworth with VPS-350 passed Caltrans safety review first submission.
We provide FHWA eligibility letters and weight certificates with every build.
Strategy 2: California-Compliant Arrow Boards & Message Signs
Caltrans Spec: 60×30 inch Type C arrow boards, full-matrix PCMS with 18-inch characters. Our Builds: Wanco or SolarTech boards pre-wired with 4-corner strobes, sequential chevrons, and auto-dimming. Options: Bilingual messaging, speed radar integration, or “YOUR SPEED” displays. Example: A Monterey night paving crew added radar-triggered “SLOW DOWN” alerts—reduced speeds 18 mph average.
All boards include 12-year no-fade warranty.
Strategy 3: Custom Lighting Packages for 24/7 Visibility
Standard Problem: Factory lights don’t meet Caltrans 10 fc work-area illumination. Our Solution: 360° LED flood packages (40,000–120,000 lumens), truck-body mounted work lights, and cab-controlled zones. Add-Ons: Take-down lights, alley lights, traffic director bars. Outcome: A Riverside bridge project maintained full visibility during fog—zero delays.
Solar-assisted packages for remote sites.
Strategy 4: Cab & Driver Safety Enhancements
Core Features:
- 4-point harnesses
- Fire suppression systems
- 360° camera packages with in-cab monitors
- Impact-activated rollover beacons
Customization: Extended cabs for crew transport, climate-controlled storage for paperwork. Result: A Phoenix driver survived 58 mph rear-end—cab intact, no injuries.
All builds meet SAE J2422 rollover standards.
Strategy 5: Fleet Branding & Identification Packages
Professional Look: Full vinyl wraps, magnetic door signs, or painted logos. Compliance: Caltrans vendor numbers, company US DOT decals, reflective striping per FMVSS 108. Example: A Bay Area contractor’s 12-truck fleet received matching wraps—improved brand recognition and professional appearance at bid walks.
Quick-change magnetic panels for multi-agency contracts.
Strategy 6: Maintenance & Compliance Documentation Built-In
Every Truck Includes:
- Laminated MASH eligibility packet
- Digital maintenance log QR code
- Annual inspection checklist binder
- Spare parts kit (fuses, bulbs, hydraulic fluid)
Support: Western Highways offers quarterly servicing—oil, filters, hydraulic checks, reflectivity testing. Result: Zero downtime from inspection failures across 420 trucks.
Why Contractors Choose Western Highways Custom Builds
- In-house fabrication in Porterville, CA—no third-party delays
- Direct dealer for Scorpion II, Verdek, TrafFix, Wanco, SolarTech
- Full electrical shop—custom wiring harnesses built to spec
- Same-day parts from $2M inventory
- Financing and lease options available
See custom builds on Instagram and YouTube Shorts.
Frequently Asked Questions
How long for a custom truck? 6–10 weeks from order to delivery; rush builds available.
Do you modify existing trucks? Yes—retrofit TMAs, lighting, and boards on customer chassis.
Financing available? Yes—0% for qualified buyers up to 60 months.
California only? No—ship nationwide; Caltrans packages popular in AZ, NV, OR.
Warranty? 1-year comprehensive + manufacturer cartridge warranties.
How do I contact Western Highways? Call (559) 785-1400 or email info@westernhighwaystrafficsafety.com.
Build the Perfect Truck for Your Jobs
Generic trucks create generic problems. Western Highways Traffic Safety builds vehicles that match your speed limits, clearance restrictions, lighting rules, and branding—delivering safety, compliance, and efficiency.
Call (559) 785-1400 or email info@westernhighwaystrafficsafety.com for your free custom spec consultation.
Visit Western Highways Traffic Safety or follow on Facebook and Medium.
Your crew deserves equipment that fits the job perfectly.
