Jul. 01, 2026
A standard electric tailgate system is usually designed for the original vehicle structure. However, when an SUV is upgraded with ballistic protection, armored glass, a reinforced rear door, or additional rear-mounted accessories, the original tailgate weight can increase dramatically.
In many armored SUV projects, the tailgate may become more than 50 kg heavier than the original design. This extra load places much higher engineering requirements on the electric struts, springs, motor, control module, mounting structure, and long-term durability of the complete power liftgate system.
For this reason, an armored SUV should not use a standard aftermarket electric tailgate kit. It requires a custom heavy-duty electric tailgate solution designed around the real tailgate weight, installation structure, opening angle, working temperature, and long-term operating conditions.
A regular electric tailgate system is developed based on the original vehicle tailgate weight. Once the vehicle is modified with ballistic protection, several problems may appear:
The original electric struts may not generate enough lifting force.
The tailgate may open slowly, stop halfway, or fail to lift.
The motor may overload during repeated operation.
The mounting brackets may suffer excessive stress.
The spring force may degrade after long-term compression.
The system may become unstable in hot or cold environments.
For B2B customers such as armored vehicle builders, SUV modification workshops, off-road upgrade shops, and vehicle conversion companies, reliability is more important than simply making the tailgate move once. The system must operate safely and consistently under heavier load conditions.
The first requirement is a high-strength mechanical structure.
For an armored SUV electric tailgate system, the heavy-duty electric tailgate strut should be designed to withstand more than 5,000N of tensile force without failure. Other critical components, such as brackets, connection parts, and supporting structures, should reach a minimum tensile strength of 6,500N.
This is important because the system is not only lifting a heavier tailgate. It must also handle repeated stress during opening, closing, stopping, and anti-pinch operation. If the structure is not strong enough, the system may work during the first installation but fail after repeated daily use.
A reliable custom solution should consider:
Real tailgate weight after modification
Tailgate center of gravity
Mounting point strength
Opening angle and travel distance
Strut stroke and force curve
Bracket material and structural reinforcement
For armored SUVs, mechanical safety should always come before appearance or installation speed.
The second requirement is long-term durability testing.
A heavy-duty electric tailgate system for armored or modified vehicles should complete more than 30,000 durability cycles under different environmental conditions, including normal temperature, 80°C high temperature, and -30°C low temperature.
This type of testing is essential because armored SUVs and off-road vehicles are often used in demanding markets, including the Middle East, Africa, Central Asia, South America, and other regions with high temperature, dust, cold weather, or rough road conditions.
Durability testing helps verify whether the system can maintain stable performance after long-term use. A qualified system should continue to open and close smoothly without abnormal noise, serious speed loss, motor overheating, or mechanical failure.
(https://www.youtube.com/embed/3a1t7dPzPPo?si=W1yEaIHTqeyMR42z)
The spring system is one of the most important parts of a heavy-duty electric tailgate strut.
For armored SUV applications, the key compression spring should undergo 96 hours of aging at 85°C while under compression. After testing, force degradation should be controlled within 10%.
This requirement matters because spring force directly affects lifting performance. If the spring force drops too much after heat exposure or long-term compression, the tailgate may become unstable, slow, or unable to open fully.
A high-performance spring system helps ensure:
Stable lifting force
Long-term opening performance
Better motor protection
Reduced overload risk
More consistent user experience
For heavy tailgates, the spring is not just a supporting component. It is a core part of the complete power liftgate engineering design.
The fourth requirement is a high-torque electric motor.
After ballistic protection upgrades, the heavier tailgate needs more driving force during both opening and closing. A normal motor may not provide enough torque, especially when the vehicle is parked on a slope, operated in cold weather, or used repeatedly in a workshop or fleet environment.
A reliable armored SUV power liftgate system should use a high-torque motor combined with an optimized control strategy. The motor performance curve should meet the required engineering specifications for the modified tailgate weight and operating range.
The control strategy should also support:
Smooth opening and closing
Anti-pinch protection
Stable speed control
Motor overload protection
Soft start and soft stop
Compatibility with the vehicle’s electrical system
For heavy-duty applications, the motor and control module must be designed as one complete system, not selected separately.
Every armored SUV project can be different. Some vehicles use ballistic glass. Some have reinforced tailgates. Some add rear spare tire carriers, off-road accessories, or special body conversion parts.
That means the correct electric tailgate solution should be customized based on the actual vehicle condition.
Before developing a heavy-duty electric tailgate system, the manufacturer should confirm:
Vehicle model and year
Original tailgate structure
Final tailgate weight after modification
Added accessories on the rear door
Installation space
Required opening height
Electrical compatibility
Target market temperature conditions
Expected usage frequency
This engineering process helps avoid the common problem of installing a standard kit on a vehicle that already exceeds the original design load.
TOMASTER specializes in custom heavy-duty electric tailgate systems for modified SUVs, armored vehicles, off-road vehicles, and vehicles equipped with rear spare tire carriers.
As a manufacturer of customized electric tailgate systems, we provide professional supporting solutions for B2B customers, including:
Armored SUV electric tailgate solutions
Heavy-duty electric tailgate struts
Custom power liftgate development
Electric tailgate solutions for rear spare tire carrier vehicles
Off-road SUV power tailgate upgrade solutions
Engineering support for vehicle conversion projects
If your project involves a heavier tailgate after armored, off-road, or rear accessory modifications, TOMASTER can help evaluate the tailgate weight, lifting force, motor requirements, structural design, and complete power liftgate solution.
In most cases, it is not recommended. A standard electric tailgate kit is designed for the original tailgate weight. After armored modification, the tailgate may become much heavier, requiring a custom heavy-duty system.
Because the added weight from ballistic protection, reinforced glass, and rear modifications increases the load on the electric strut. A stronger strut helps maintain stable lifting force and long-term reliability.
Key tests should include tensile strength testing, durability cycle testing, high-temperature testing, low-temperature testing, spring aging testing, motor performance testing, and full vehicle installation testing.
The supplier should confirm the vehicle model, year, modified tailgate weight, rear accessories, installation space, opening angle, target market, and expected usage frequency.
Armored vehicle manufacturers, SUV modification workshops, off-road conversion companies, car electronics distributors, and B2B automotive accessory suppliers may need customized heavy-duty power liftgate systems.
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