11 hours ago
Why Retrofit Instead of Buying New
Landfill compactors are essential for maximizing airspace and reducing the volume of waste. Purpose-built machines like the Caterpillar 816 or BOMAG BC1172RB are effective but expensive, often exceeding $300,000 for a new unit. For smaller operations or private landfills, retrofitting existing equipment offers a cost-effective alternative. By repurposing a forestry machine or scraper chassis, operators can build a customized compactor tailored to their site’s needs.
In one notable conversion, a mid-1980s Caterpillar 518 feller buncher was transformed into a landfill compactor using salvaged components and local fabrication. The total cost came in nearly $10,000 below the price of a used set of Caron wheels alone.
Choosing the Base Machine
The Caterpillar 518 was originally designed as a forestry skidder and later adapted into a feller buncher with a boom-mounted shear. Its robust frame, articulated steering, and high ground clearance made it an ideal candidate for landfill duty.
Key features of the 518:
Sourcing and Fabricating Components
The conversion required several major components:
During testing, the machine was able to blade and compact simultaneously. The oscillation joint allowed the wheels to maintain ground contact over uneven terrain, though it occasionally caused the blade to self-angle on slopes.
Performance and Field Results
After deployment, the homemade compactor achieved a compaction ratio of approximately 10:1—comparable to mid-range commercial units. It was used to process bulky waste from a motorhome manufacturing plant, including foam, plastic, and wood scraps.
Operational highlights:
Lessons Learned and Design Improvements
While the conversion was successful, several areas were identified for improvement:
The landfill was originally started to support a mobile home company and later acquired by a motorhome manufacturer. It became a model site in Mississippi, frequently visited by state officials and industry representatives. Strict waste protocols were enforced—no household garbage or chemicals allowed. Even a single soda can could trigger a $25,000 fine.
The team behind the compactor emphasized pride in their work and the importance of innovation in waste management. As one operator put it, “It’s Christmas every day—just not the kind with wrapping paper.”
Conclusion
Converting a feller buncher into a landfill compactor demonstrates the power of ingenuity and resourcefulness in heavy equipment operations. With careful planning, salvaged parts, and skilled fabrication, a customized machine can rival commercial units at a fraction of the cost. Whether compacting foam or pushing fill, this homemade rig proves that necessity still drives invention—and that the landfill business, when done right, is anything but trashy.
Landfill compactors are essential for maximizing airspace and reducing the volume of waste. Purpose-built machines like the Caterpillar 816 or BOMAG BC1172RB are effective but expensive, often exceeding $300,000 for a new unit. For smaller operations or private landfills, retrofitting existing equipment offers a cost-effective alternative. By repurposing a forestry machine or scraper chassis, operators can build a customized compactor tailored to their site’s needs.
In one notable conversion, a mid-1980s Caterpillar 518 feller buncher was transformed into a landfill compactor using salvaged components and local fabrication. The total cost came in nearly $10,000 below the price of a used set of Caron wheels alone.
Choosing the Base Machine
The Caterpillar 518 was originally designed as a forestry skidder and later adapted into a feller buncher with a boom-mounted shear. Its robust frame, articulated steering, and high ground clearance made it an ideal candidate for landfill duty.
Key features of the 518:
- Articulated frame with oscillation joint
- Rear-mounted engine for better weight distribution
- Hydraulic system compatible with blade and compaction functions
- Heavy-duty planetary axles
Sourcing and Fabricating Components
The conversion required several major components:
- Blade: Sourced from a Clark 290M scraper, modified to fit the 518’s front frame
- Wheels: Taken from two Hyster rollers, repurposed into steel compaction drums
- Mounting hardware: Custom brackets and gussets fabricated in-house
- Hydraulic lines: Rerouted and extended to accommodate blade tilt and lift
During testing, the machine was able to blade and compact simultaneously. The oscillation joint allowed the wheels to maintain ground contact over uneven terrain, though it occasionally caused the blade to self-angle on slopes.
Performance and Field Results
After deployment, the homemade compactor achieved a compaction ratio of approximately 10:1—comparable to mid-range commercial units. It was used to process bulky waste from a motorhome manufacturing plant, including foam, plastic, and wood scraps.
Operational highlights:
- Blade effective for pushing loose material and shaping slopes
- Compaction wheels penetrated and crushed waste layers
- Articulated steering allowed tight turns in confined cells
- Maintenance costs remained low due to mechanical simplicity
Lessons Learned and Design Improvements
While the conversion was successful, several areas were identified for improvement:
- Visibility: The blade was partially obscured by the boom arm, limiting precision
- Oscillation: Rear axle lacked oscillation, reducing stability on uneven fill
- Blade control: Hydraulic response could be improved with flow restrictors
- Weight distribution: Additional ballast may enhance compaction force
- Rear axle oscillation retrofit for better ground contact
- Relocation of operator cab or boom arm for improved visibility
- Installation of GPS or laser guidance for blade grading
- Use of modular cleats on wheels for adjustable compaction profiles
The landfill was originally started to support a mobile home company and later acquired by a motorhome manufacturer. It became a model site in Mississippi, frequently visited by state officials and industry representatives. Strict waste protocols were enforced—no household garbage or chemicals allowed. Even a single soda can could trigger a $25,000 fine.
The team behind the compactor emphasized pride in their work and the importance of innovation in waste management. As one operator put it, “It’s Christmas every day—just not the kind with wrapping paper.”
Conclusion
Converting a feller buncher into a landfill compactor demonstrates the power of ingenuity and resourcefulness in heavy equipment operations. With careful planning, salvaged parts, and skilled fabrication, a customized machine can rival commercial units at a fraction of the cost. Whether compacting foam or pushing fill, this homemade rig proves that necessity still drives invention—and that the landfill business, when done right, is anything but trashy.
