How Car & Commercial Increased Van Conversion Capacity with LEGEND Eclipse

When you're converting commercial vehicles at scale, every kilogram and every labour hour matters.

For Car & Commercial, the goal was simple: find a van conversion solution that delivered better quality, reduced vehicle weight and improved efficiency. What the team discovered was that LEGEND’s Eclipse flooring system and EconoLite liners did the job improving the finished vehicle.

Reduce Weight Without Compromising Quality

Like many vehicle converters, Car & Commercial had been using traditional plywood flooring and bulkheads for years. Although functional, these builds relied on heavy 18mm components that added unnecessary weight and took significant time to install.

The business wanted a lighter, higher-quality alternative that would improve payload for fleet customers while making the installation process more efficient.

Saving Almost 180kg Per Van

Replacing the previous conversion with a LEGEND kit—including Eclipse flooring and EconoLite liners—dramatically reduced the finished vehicle's weight.

The complete conversion now weighs approximately 195kg, representing a saving of almost 180kg.

For fleet operators, that weight reduction translates directly into increased payload capacity. For electric vans, every kilogram saved becomes even more valuable, helping maximise vehicle efficiency and operational flexibility.

Faster Van Conversions with Eclipse Flooring

The job's easy because the kit fits.

Originally, the team expected each conversion to take around 32 labour hours. Today, those same builds are completed in approximately 22 hours, saving around 10 labour hours.

For a busy commercial vehicle workshop, that improvement creates significant capacity.

We've got a massive saving, and it means it's an extra vehicle a week.

Supporting the Future of Electric Van Conversions

Since opening in 2008, Car & Commercial has built its reputation on developing skilled technicians and adapting to changing vehicle technology.

Today, approximately 90% of the company's work focuses on electric vehicle conversions.

Car & Commercial invested in EV conversions several years before much of the market, allowing the team to refine processes while many competitors are still adapting.

Everybody else is just starting to work with it. We're starting to perfect it.

With lightweight conversion systems becoming a key driver of this strategy, LEGEND is proud to be a trusted partner in advancing this initiative.

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