Modifying Track Shoes for Better Maneuverability and Terrain Adaptation

[MikePhua]

The Role of Track Shoes in Crawler Equipment
Track shoes, also known as grousers, are bolted to the chains of crawler machines such as dozers, excavators, and pipelayers. Their width, thickness, and profile directly affect ground pressure, traction, flotation, and turning radius. Wider shoes reduce ground pressure and improve flotation on soft terrain, while narrower shoes enhance maneuverability and reduce stress on undercarriage components in rocky or confined areas.
Manufacturers like Caterpillar, Komatsu, and Liebherr offer a range of shoe widths tailored to specific applications. For example, swamp dozers may use shoes up to 36 inches wide, while standard construction dozers typically run 20–24 inch shoes. However, field conditions often demand customization beyond factory specs.
Why Cut Track Shoes Shorter
Operators may choose to cut track shoes shorter for several reasons:

• Improve turning radius in tight spaces
  
• Reduce side drag on hard or uneven terrain
  
• Minimize shoe overlap and interference during pivot turns
  
• Lower stress on final drives and steering clutches
  
• Adapt to rocky or root-laden environments where wide shoes snag
  

In forestry operations, for instance, wide shoes can catch on stumps and roots, causing abrupt stops or damage. A contractor in Oregon shortened his shoes by 4 inches and reported smoother turns and less undercarriage wear during thinning work.
Methods for Cutting and Reprofiling Shoes
Shortening track shoes requires precision and awareness of structural integrity. Recommended steps include:

• Remove shoes from track chains and clean thoroughly
  
• Mark cut lines using a jig or template to ensure uniformity
  
• Use plasma cutter or oxy-acetylene torch for initial cut
  
• Grind edges smooth and bevel corners to reduce stress risers
  
• Drill new bolt holes if repositioning is needed
  
• Reinstall with torque specs and inspect for alignment
  

Avoid cutting shoes while mounted, as heat and vibration can damage adjacent components. Always wear protective gear and ensure fire suppression tools are nearby.
A technician in Alberta used a CNC plasma table to shorten 36 shoes for a D5 dozer. The shoes were cut to 18 inches and beveled for root clearance. The machine performed better on steep grades and showed reduced fuel consumption.
Impact on Performance and Wear Patterns
Shorter shoes change how the machine interacts with the ground:

• Reduced surface area increases ground pressure slightly
  
• Turning becomes more responsive, especially in confined zones
  
• Side wear on shoes and links may decrease
  
• Traction may drop on soft or wet terrain
  

Operators should monitor wear patterns after modification. Uneven wear may indicate misalignment or improper shoe spacing. It’s also important to check for increased vibration or noise, which could signal stress on the undercarriage.
In Finland, a contractor shortened the shoes on a pipelayer to navigate narrow trench corridors. The machine’s steering improved, but traction on clay banks declined. He compensated by adding cleats to the shoe surface for grip.
Alternatives to Cutting Shoes
Before committing to cutting, consider these alternatives:

• Swap to narrower OEM shoes from another model
  
• Use bolt-on extensions or removable cleats for seasonal adaptation
  
• Install segmented shoes with flexible ends
  
• Adjust track tension and chain alignment to reduce drag
  

Some manufacturers offer modular shoe kits that allow quick width changes. These are ideal for rental fleets or multi-terrain operations.
A crew in Thailand used segmented shoes on a Komatsu D31 to switch between rice paddies and gravel roads. The system allowed them to change shoe width in under two hours, improving versatility and reducing downtime.
Safety and Structural Considerations
Cutting shoes alters load distribution and may affect warranty coverage. Always consult the equipment manual and manufacturer guidelines. Key safety tips:

• Do not cut into bolt holes or weld zones
  
• Maintain minimum shoe thickness to prevent flexing
  
• Avoid sharp corners that can crack under load
  
• Inspect shoes after 50 hours of use for signs of fatigue
  

A mining operator in Alaska shortened his shoes without beveling the edges. Within weeks, cracks appeared near the bolt holes. After switching to properly profiled shoes, the issue was resolved.
Stories from the Field
In Texas, a contractor working on pipeline right-of-way shortened the shoes on his D6N to navigate narrow easements. The modification allowed tighter turns and reduced turf damage, helping him meet environmental compliance targets.
In New Zealand, a vineyard operator modified his crawler tractor’s shoes to fit between vine rows. The narrower profile improved maneuverability and reduced root disturbance, leading to healthier crops and better yield.
Conclusion
Cutting track shoes shorter can be a practical solution for improving maneuverability and adapting to specific terrain challenges. When done correctly, it enhances machine performance without compromising safety or durability. Whether navigating forest trails, trench corridors, or agricultural rows, customized shoes offer a tailored approach to traction and control—proving that even small changes underfoot can make a big difference in the field.