Jul. 22, 2026
Armored SUVs, off-road vehicles and expedition builds often carry additional tailgate-mounted weight. After installing ballistic glass, armor protection, rear spare tire carriers, ladders or storage accessories, the tailgate can become significantly heavier than the original factory design.
In some heavy-duty vehicle projects, the added tailgate load may reach approximately 30–80 kg, depending on the vehicle model, armor level, spare tire size and mounting structure.
This extra load changes the tailgate’s center of gravity and increases the torque required to open, hold and close the tailgate. As a result, the original power liftgate system may fail or become unsafe.
A reliable heavy-duty electric tailgate system must therefore be tested as an engineering system, not judged only by motor power or strut force.
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A heavy-duty electric tailgate system for armored SUVs should pass mechanical strength, corrosion resistance, waterproof protection, temperature durability, lateral load and impact resistance tests.
These tests help verify whether the electric tailgate struts, brackets, motor, transmission components and control system can operate reliably under high-load, harsh-environment and long-term use conditions.
For TOMASTER heavy-duty electric tailgate projects, the following test items may be used as project validation requirements, depending on vehicle configuration and customer application.
Factory power liftgate systems are designed around the original tailgate weight, hinge geometry and center of gravity.
After major vehicle modifications, common failures may include:
Tailgate stops halfway during opening
Tailgate drops after reaching the open position
Electric struts bend or deform
Motor current rises abnormally
Tailgate cannot complete repeated opening and closing cycles
Hinges or mounting brackets become overloaded
Anti-pinch function becomes inaccurate
Strut transmission components wear prematurely
For this reason, a customized heavy-duty power tailgate must be validated through controlled testing before delivery.
A heavy-duty electric tailgate strut must withstand high mechanical load without fracture, separation or structural failure.
Example testing requirements:
Electric tailgate strut tensile strength: 5000 N without fracture
Brackets and connecting components tensile strength: ≥6500 N
This test helps confirm whether the strut body, rod, end joints, brackets and mounting hardware can tolerate the increased forces generated by a heavier tailgate.
For armored SUVs and vehicles with rear spare tire carriers, tensile strength is especially important because the tailgate may experience higher loads during opening, closing, vibration and road impact.
Armored vehicles and off-road SUVs may operate in humid, coastal, rainy or high-salinity environments. Corrosion can weaken brackets, fasteners, housings and electrical connectors over time.
A heavy-duty electric tailgate system should therefore undergo corrosion resistance testing.
Example requirement:
480-hour Neutral Salt Spray Test
Appearance evaluation according to GB/T 6461
Target result: Grade 9 appearance
This helps verify coating quality, surface protection and long-term corrosion resistance for metal components.
Electric tailgate systems include motors, connectors, control wiring and transmission assemblies. These components must remain protected against rain, water splash and temporary water exposure.
Example requirement:
Tested according to GB/T 4942.2 IP67
System continues operating normally after waterproof validation
IP67 protection is important for off-road vehicles, rescue vehicles, armored SUVs and vehicles used in outdoor or harsh environments.
Waterproof testing helps reduce the risk of motor failure, connector corrosion, short circuit and unstable operation.
A professional heavy-duty power liftgate system must operate repeatedly under different temperature conditions.
Example durability validation:
20,000 cycles at 23 ±2°C
5,000 cycles at 80 ±2°C
5,000 cycles at −30 ±2°C
Total durability target: 30,000 operating cycles
This test evaluates long-term motor performance, internal screw transmission stability, spring behavior, lubrication performance, seal reliability and electronic control durability.
Testing at high and low temperatures is especially important for vehicles used in the Middle East, Central Asia, North America, Northern Europe and other extreme-climate markets.
A tailgate strut does not only experience axial force. In real vehicle use, vibration, body movement, uneven road surfaces and imperfect installation angles can create side loads.
Example lateral load test:
Electric tailgate strut installed horizontally
20 kg load suspended from the center of the strut
Test duration: 24 hours
Acceptance requirement: no permanent deformation
This test helps evaluate sleeve strength, internal structure rigidity and resistance to bending under abnormal or side-load conditions.
For off-road and armored vehicles, lateral load resistance is important because the vehicle may operate on slopes, rough roads and uneven terrain.
During transportation, installation and workshop handling, electric tailgate struts may be exposed to impact. Drop testing helps verify whether the structure remains intact after accidental shock.
Example drop test requirement:
Unpackaged product dropped freely from 1.5 meters
Test repeated twice
Product remains structurally intact
Electric tailgate strut operates normally after testing
This test helps identify housing weakness, internal looseness, connector damage and abnormal operating noise after impact.
Component tests are important, but they are not enough by themselves. A heavy-duty electric tailgate system should also be validated on the actual modified vehicle.
Recommended vehicle-level tests include:
Opening and closing cycle test
Hold-position stability test
Operation on slope
Anti-pinch force verification
Motor current and temperature monitoring
Latch engagement test
Height memory function test
Manual emergency operation test
Noise and vibration evaluation
Hinge and bracket stress inspection
Vehicle-level validation confirms whether the complete system performs correctly under real installation conditions.
Before designing or testing a heavy-duty electric tailgate system, engineers should confirm:
Vehicle model and production year
Original tailgate weight
Final tailgate weight after modification
Added armor or accessory weight
Tailgate center of gravity
Hinge geometry
Electric strut mounting angle
Required opening height
Required opening and closing speed
Electrical system capacity
Environmental requirements
Target durability cycles
Safety requirements and anti-pinch thresholds
This information allows the system to be engineered according to real vehicle conditions.
A heavy-duty electric tailgate for armored SUVs must do more than lift a heavier tailgate. It must remain structurally strong, corrosion-resistant, waterproof, durable under temperature extremes and stable under side-load and impact conditions.
For vehicles upgraded with ballistic glass, armor protection, rear spare tire carriers or off-road accessories, the factory power liftgate system may not be suitable for the increased load.
TOMASTER AUTO PARTS specializes in customized heavy-duty electric tailgate systems for armored SUVs, rear spare tire carrier conversions and off-road vehicle modifications. Our engineering approach focuses on measured vehicle data, component testing and vehicle-level validation to restore reliable automatic tailgate operation after major vehicle upgrades.
