Celebrating 10 Years of the Drop & Go® Traffic Management Vehicle

The year 2014 was a really significant time for Advanced KFS Special Vehicles. We began a conversation with HTM Traffic Management that, looking back, was set to completely change how a Traffic Management Vehicle (TMV) was designed and built. Before this, the market largely relied on simple conversions, standard drop sides that had been fitted with essentials like lightbars and cone wells. 

These did the job, of course, but focusing too much on keeping costs down often meant that safety, payload, and the integrity of the design were compromised.

That initial chat between HTM’s Martyn Long and our founder Ian Knight was the spark. It kicked off a brilliant period of collaboration, innovation, and engineering mastery that has now lasted a decade. This partnership led directly to the Drop & Go® Traffic Management Vehicle, which is a purpose-built, low-floor TMV conversion. It genuinely reset industry expectations and set a new, high standard for the sector. 

This solution successfully blends operator safety, intelligent design, and long-term reliability, which is why you see it used successfully across fleets all over the country.

Why Traditional Conversions Were Causing Issues

Before the Drop & Go® TMV came along, most Traffic Management Vehicles were constructed using standard dropside bodies bolted onto regular chassis cabs. Some low-floor options existed, but the truth is they were never specifically designed to handle the serious structural demands of daily Traffic Management work. Using platform cabs as the base created some major weaknesses, including poor load distribution, excessive flexing of the body, and, in some genuine operational scenarios, the chassis actually cracked or failed.

These structural problems weren't the fault of the operators; they were simply limitations of the way the vehicles were designed. A platform cab just isn't the right starting point for a truly low-floor Traffic Management Vehicle, and traditional conversions were always going to run into challenges over time.

Here at AKFS, our extensive knowledge of these limitations, combined with our strong and long-standing partnership with AL-KO Kober, allowed us to engineer a purpose-built low-floor chassis conversion that completely solved those weaknesses. 

The result is a vehicle that is safer, lighter, and much more durable. It performs reliably every day, and we are incredibly proud that, as far as we know, the structural chassis of not one single AKFS-built Drop & Go® TMV has failed in ten years of hard work.

The Journey to a Smarter Design

Working very closely with HTM, Ian Knight and Martyn Long started by carefully analysing HTM’s existing vehicles. Ian immediately saw opportunities to improve the strength, cut down the overall weight, and streamline the construction process, all without losing any essential functionality. The very first prototype used heavy galvanised steel and powder-coated parts, which were quite labour-intensive to produce.

Ian’s main focus was to apply the AKFS “Built Without Compromise” philosophy to the project. This means our approach is always focused on engineering integrity and delivering real, lasting value, rather than just aiming for the cheapest price tag. After the initial prototype successfully proved the whole concept, the next generations of Drop & Go® vehicles were engineered "the AKFS way," quickly setting a new standard for quality.

A Crucial Engineering Collaboration

The story of the Drop & Go® TMV is one of teamwork and shared expertise. AKFS has been working with AL-KO Kober since 2003, using their low-floor AL-KO chassis conversion as the strong base for many of our specialist vehicle platforms. Given Ian’s deep background in chassis design, which goes all the way back to 1994, AKFS was in a unique position to work directly with AL-KO engineers. We were able to strengthen key areas of the chassis specifically to handle the particular demands of Traffic Management work.

This important collaboration resulted in a highly refined, purpose-built foundation. It has an impeccable record, with zero structural failures—a true reflection of the combined expertise and strong partnership that powers the entire Drop & Go® range.

Designed with a Clear Goal, Always Built Without Compromise

Every single feature of the Drop & Go® Traffic Management Vehicle is meticulously engineered for function, safety, and ease of use. We don't add anything unnecessarily, and we certainly don't overbuild it. Some of the thoughtful design characteristics include:

AL-KO low-floor chassis conversion - This foundation has three important modifications: an uprated rear axle, extra reinforcement plates, and strengthened floor supports. These elements are subtly hidden from view but add enormous value to its operation.

Structural bulkhead and GRP cowling - Designed right here in-house to drastically increase rigidity, and supported by stainless steel gussets for optimal load distribution.

Non-slip aluminium floor sections - Specified by AKFS and secured using a huck-bolted and bonded process for long-term durability.

Water-tight aluminium wheelboxes - These are constructed from 3mm aluminium and feature water-tight doors to prevent moisture build-up and mould. They also cleverly hold the stainless steel brackets that carry the sliding GRP handrails when not in use, a small but incredibly practical detail that makes daily work simpler and safer.

Innovative GRP handrail system - This features a flexible, interlocking design with tough stainless steel brackets and precision-manufactured joints for completely reliable performance.

Optimised tie-down points - These were developed after consulting with HTM to ensure the most secure load restraint across both the floor and the bulkhead positions.

Controlled dropside dimensions - The size is carefully set to help prevent overloading and maintain operational safety across your fleet.

Reinforced beacon and work-light mounts - These are strength-tested for stability, even when driving at motorway speeds.

Signature tailgate design - Inspired by our popular AKFS Plant & Go® range and perfectly refined for Traffic Management work. This feature is genuinely loved by everyone who uses it and is often copied, but never truly replicated.

Every element of this design is more than just good engineering; it’s a reflection of ten years of hands-on experience. This unwavering attention to detail, built into the very heart of every Drop & Go® TMV, is what truly distinguishes Advanced KFS from other converters and embodies our Built Without Compromise approach to specialist vehicle conversions.

Setting a New, Higher Standard for the Industry

Over the last decade, the Drop & Go® Traffic Management Vehicle has successfully set a new standard for safety, performance, and reliability across the UK’s entire Traffic Management sector. Its success truly lies in the details, from the incredibly strong chassis design that you can't see, to the intuitive controls that operators appreciate every day.

Where traditional conversions often prioritised simply being the cheapest, the AKFS Drop & Go® prioritised long-term value, and that crucial distinction is what makes it so different. Built using decades of experience, thoroughly tested in real-world scenarios, and constantly improved, it has made the Traffic Management industry safer, more efficient, and much more professional.

The Legacy Continues

Ten years on, the Drop & Go® TMV is still considered the definitive standard for purpose-built Traffic Management Vehicles. The collaboration between HTM, AL-KO Kober, and AKFS didn't just create a product; it created a lasting legacy of design excellence.

We may not have personally laid a traffic cone, but we absolutely know how to build the UK’s most capable low-floor Traffic Management Vehicle. Our deep understanding of the challenges faced by operators, combined with decades of specialist chassis design experience, guarantees that every single Drop & Go® delivers unwavering performance, reliability, and safety exactly where it matters most.

Over the last decade, the Drop & Go® has earned the trust of operators and fleet managers across the whole of the UK’s highways network. 

Serving everyone from local councils to major contractors, each vehicle represents thousands of operational hours without structural failure or compromise; it’s solid proof of what true engineering knowledge can achieve when applied with a clear purpose. This proven performance record continues to establish Advanced KFS as the UK’s leading specialist in low-floor Traffic Management Vehicle conversions.

For us at AKFS, “Built Without Compromise” is more than a company principle; it’s the commitment behind every single specialist vehicle we engineer and build.

If you're ready to discuss how the Drop & Go® range can integrate with your existing fleet or if you simply have questions about your specific traffic management vehicle needs, please get in touch with our friendly team.