How To Choose the Best Material for Custom Ute Tray – 7 Factors to Consider

Need a custom Ute tray that works as hard as you do? Not one that quietly steals your payload or sends you back to the workshop? You’re in the right place.

Choosing the best material for a custom Ute tray shouldn’t feel like a gamble, but for a lot of Ute owners, it does. Pick wrong and suddenly you’re overweight, fighting rust, or parked up waiting on repairs. Ask five tradies and you’ll get five different opinions, usually based on personal preference, rather than how you actually use your vehicle. Helpful? Not always.

This guide breaks down the real factors you need to consider when choosing a custom Ute tray material, so you can pick the right tray for your day-to-day work, not someone else’s setup.

Keep reading and you’ll know exactly what to ask and how to choose a Ute tray that won’t cost you payload, time, or money.

What is a Custom Ute Tray? Why the Material Truly Matters

A custom Ute tray (also called a service body or tray body) is an aftermarket replacement for the factory tub that gives you a stronger, more flexible cargo platform. Ute trays are built for real work. They resist denting and scratching better than tubs. They increase usable load area and mostly include removable side rails, integrated toolbox mounts and purpose-built tie-down points.

Choosing the best Ute tray material is a long-term decision that affects everyday performance, safety and running costs in Perth’s unique conditions.

How Ute tray material changes everything:

The material used in your Ute trays influences how the tray behaves over its entire lifespan, not just how it looks on day one. It determines how the tray responds to daily loading, how it ages in Perth’s climate, and how easy it is to modify, repair or resell later.

While many trays can look similar from the outside, differences in material type, thickness and structural design can dramatically change how a tray performs once it’s loaded with tools, equipment or recreational gear. That’s why two trays with similar dimensions can deliver very different real-world results.

Common Types of Materials for Custom Ute Trays

Most aftermarket trays use steel, aluminium (alloys), or a hybrid approach (steel frame + aluminium deck). Each material has clear trade-offs. Pick the one that aligns with how you actually use your vehicle.

1- Aluminium Ute Trays

Aluminium trays commonly weigh 60–150 kg less than an equivalent steel tray, depending on design and accessories. That weight drop helps payload and fuel economy, which is ideal for fleets and touring 4WDs.

Aluminium resists rust naturally, but it’s generally more expensive up front. It can require specialist repair after heavy impact. Flat pack aluminium Ute trays are a popular lightweight option for quicker delivery and simple installs.

2- Steel Ute Trays

Steel is commonly quoted as being around three to four times stronger/stiffer than aluminium grades. This makes it the top choice for trades that regularly haul heavy or abrasive loads. Steel is also usually cheaper to buy and far easier to fix in the field (cut/weld/patch).

Steel trays are heavier; almost 2× the weight of an aluminium tray, which reduces payload and can affect fuel use. Steel also needs proper corrosion protection like galvanising, quality paint or powder coat and a maintenance plan in coastal WA.

3- Hybrid Builds

A hybrid tray pairs a steel structural frame (for tie-down strength and repairability) with an aluminium deck (for weight saving and corrosion resistance). For mixed-use tradies who also tour on weekends, hybrids can be an ideal compromise.

7 Key Factors to Consider When Choosing a Custom Ute Tray Material

The right custom Ute tray isn’t chosen on brand name or price alone; it should be selected based on how you use your vehicle every day. Below are seven practical, real-world factors you should consider before committing. Each one directly affects performance, compliance, running costs, and long-term value.

Factor 1: Ute Tray Weight & Its Impact on Payload & GVM

The weight of the Ute tray is one of the most important and often overlooked considerations when choosing a custom Ute tray.

The material you pick and the accessories you add directly reduces usable payload and can push your vehicle closer to, or over, its Gross Vehicle Mass (GVM) limit.

In simple terms, every kilo your tray adds is a kilo less for tools, materials or passengers. Aluminium builds typically save 60–150 kg versus similarly specified steel trays depending on design and fitted accessories. A difference that matters on a busy Perth site or a long fleet run.

Additionally, heavier trays also increase fuel use and tyre/wear costs over time, so weight affects both compliance and operating expense.

Mini worked example: if your dual-cab Hilux has 1,100 kg usable payload, swapping a steel tray for an aluminium tray that’s 120 kg lighter leaves you with an extra 120 kg for gear or materials. And this is the equivalent of another person and a full kit.

Quick practical checks:

• Always ask the builder for the tare weight in writing, including any fitted accessories.
• Subtract this from your vehicle’s GVM to confirm your usable payload.
• If you’re unsure of your vehicle’s kerb weight or limits, a professional tray builder should help you verify this.

Factor 2: Ute Tray Strength and Durability for Real Work Conditions

The durability of Ute tray isn’t just about marketing claims; it’s about how the tray performs under repeated heavy loads, point impacts, and day-to-day abuse.

Steel generally offers higher yield strength and stiffness, making it more resistant to denting, flexing, and impact damage. It performs exceptionally well when carrying heavy machinery, construction materials, or supporting ladder racks and welded mounts. In fact, steel is approximately four times stronger than aluminium and around three times stiffer, making it ideal for demanding applications.

Aluminium trays are lighter but can flex or suffer localised damage if not properly engineered. High-quality aluminium trays compensate with reinforced extrusions and structural frames, but build quality matters significantly.

What to verify with the builder:

• Plate thickness (mm) and frame section sizes
• Whether the structure uses engineered extrusions or folded sheet
• Tie-down point ratings and placement; welded to the frame or bolted to sheet?
• Repair options as steel trays are typically easier to cut and weld on-site, reducing downtime

If your work involves construction, mining, plant hire, or heavy transport, prioritise frame strength and repairability over weight savings.

Factor 3: Corrosion Resistance and Perth Weather Conditions

If you live in Perth, you must account for coastal salt air, UV exposure, red dust, and harsh worksite environments. Corrosion resistance plays a major role in long-term durability and resale value.

Aluminium naturally resists rust and performs exceptionally well in coastal environments. Steel trays can also be durable, but only when protected with the correct surface treatments such as hot-dip galvanising, quality paint systems, or powder coating, combined with regular maintenance.

Practical maintenance considerations:

• For steel trays, regularly inspect welds and edges, repair paint chips early, and consider galvanised underframes for coastal use.
• For aluminium trays, rinse salt buildup periodically and ensure dissimilar metals are isolated to prevent galvanic corrosion.

While no material is immune to weather damage, aluminium offers the highest natural corrosion resistance, making it a strong choice for Perth’s coastal and outdoor conditions.

Factor 4: Ute Tray Cost vs Long-Term Value

When evaluating the cost of Ute tray, it’s essential to look beyond the upfront price and consider total cost of ownership.

Typically, aluminium Ute trays cost around 30% more than mild steel trays, largely due to raw material and fabrication costs. Exotic aluminium alloys can increase prices further. However, aluminium trays require less corrosion maintenance and may deliver fuel savings over time.

Steel trays generally cost less initially and are cheaper to repair after impact damage. However, ongoing maintenance, repainting, or rust treatment can increase long-term expenses — particularly in coastal WA.

Smart budgeting tips:

• Compare quotes with identical specifications
• Ask about repair scenarios and replacement part costs
• Consider resale value as lighter, corrosion-free trays hold value better in Perth markets

Cost should never be the only deciding factor, but it should be weighed carefully against performance and longevity.

Factor 5: Compatibility with Toolboxes, Canopies & Tray Covers for Utes

If you plan to add toolboxes, canopies, drawer systems, or tray covers for Utes, material choice matters.

Steel trays offer more flexibility for welded mounts and structural modifications. Aluminium trays rely on bolted systems, which must be correctly sealed and isolated to avoid corrosion between steel fasteners and aluminium surfaces.

Accessory compatibility checklist:

• Are toolboxes mounted to the frame or deck?
• Are canopy rails integrated or retrofit-friendly?
• Are wiring and plumbing provisions included for lights, water tanks, or electrics?

Planning accessories early avoids expensive retrofits and unnecessary weight increases later.

Read more > Ute Tray Accessories to Enhance Efficiency

Factor 6: Your Vehicle Use (Tradie vs 4WD vs Fleet)

There’s no single “best” material — only the right custom Ute tray for your use case.

• Trades & construction: Strength, durability, and repairability — steel or steel-frame hybrids
• Fleet vehicles: Weight reduction and fuel efficiency — aluminium or lightweight hybrids
• Touring & 4WD: Corrosion resistance and payload — aluminium or hybrid setups

Avoid choosing based on trends. The best Ute tray material is the one that suits how your vehicle is used every single day.

Factor 7: Customisation, Installation Quality & Local Support

A high-quality custom Ute tray should include correct chassis mounting, professional welding, compliant tie-down points, and a clear warranty. Perth-based fabrication offers advantages in turnaround time, local support, and compliance knowledge.

While aluminium trays are generally easier to install due to their lighter weight, professional installation is strongly recommended for both materials. Installation involves heavy components and precise mounting as mistakes can affect safety, compliance, and tray lifespan.

Steel vs. Aluminium Ute Trays: Quick Comparison

If you want a deep side-by-side comparison, see our related guide on aluminium vs steel Ute trays.

Before Your Buy: Important Questions to Ask Your Ute Tray Supplier

• What’s the tare weight of this tray with my planned accessories (toolboxes, racks, water tanks)?
• How will this tray affect my vehicle’s GVM and usable payload?
• What corrosion protection and finish do you include for Perth conditions (galvanised, powder coat, etc.)?
• Can I mount my toolbox, canopy or tray covers later — and how will they be fitted?
• What is the plate thickness, frame section sizes and rated tie-down point specifications?
• If the tray is damaged, what’s the likely repair cost and turnaround time (local repair options)?
• What warranty, lead time, installation process and post-fit support/ certification do you provide?

Expert Tips to Choose the Right Custom Ute Tray

Follow these tips to avoid costly mistakes.

➤ Don’t max out payload on day one

Leave a safety buffer; at least 10–15% of your rated payload so you can carry unexpected tools, materials, or an extra passenger without breaching GVM. Overloading leads to fines, increased wear and unsafe handling.

➤ Plan accessories early

Mounting points, wiring, and weight all change the tray’s final specs. Design the tray around the toolbox/canopy/drawers you plan to install. Retrofits cost more and add unexpected weight.

➤ Ask for tare weight in writing

Don’t accept rough estimates. A written tare weight (tray + fitted boxes, racks, etc.) lets you calculate usable payload precisely and prevents nasty surprises at registration or weigh stations.

➤ Choose repairability if downtime costs money

If your trade loses revenue when the vehicle’s out of action, favour designs that are easy to repair locally. Steel frames and simple welded mounts are quicker and cheaper to fix on-site than specialist aluminium panels.

➤ Think total cost of ownership – not just purchase price

Aluminium often costs more up front (typically 20–50% more depending on alloy and finish) but needs less corrosion maintenance. Steel is cheaper initially and easier to repair. Compare likely repair, maintenance and fuel costs over the tray’s life.

➤ Prioritise rated tie-downs and structural mounting

Check where tie-down points are fitted. Welded to structural cross-members is better than bolted to thin decking. Properly rated tie-downs matter for safety and compliance on job sites.

Sick of losing payload to an overweight tray or watching rust eat your investment?

Find the Best Custom Ute Trays and Accessories at Perth 4WD Today

Perth 4WD is your one-stop shop for Ute trays, 4WD parts and accessories in Perth, WA.

We supply and fit Perth-made Glennic Transport Equipment steel trays, built from predominantly galvanised steel for superior strength, corrosion resistance and long service life.

Whether you need a new steel tray, want to recondition an existing tray, or are adding toolboxes, canopies or under-tray drawers, our experienced team helps you choose a setup that suits your workload, budget and GVM.

Get a Free Quote Now

FAQs About Custom Ute Tray Material

Q1: What is the best material for a custom Ute tray?

The best Ute material depends on use. Steel is best for heavy, impact-prone work (easier on-site repairs). Aluminium is best for weight savings and coastal corrosion resistance. Hybrid (steel frame + aluminium deck) is a strong compromise for mixed-use.

Q2: Are aluminium Ute trays better than steel?

Better depends on priorities. Aluminium is lighter and resists rust but is usually more expensive up front and may require specialist repair – good for fleets and coastal WA. Steel is heavier but stronger for point loads and cheaper to repair – better for tradies and heavy payloads.

Q3: How much does a custom Ute tray weigh?

Weights vary by size and build. Typical ranges: aluminium trays 70–200 kg, steel trays 250–400+ kg for similar-sized dual-cab trays. Aluminium commonly saves 60–150 kg versus steel depending on design and accessories. Always get the tare weight in writing for your exact model.

Q4: How long does a new Ute tray last?

With proper maintenance, both aluminium and quality steel trays can last 10+ years. Aluminium requires less corrosion maintenance; steel needs good coatings (galvanised/powder coat) and regular touch-ups in coastal or chemical-exposed sites. Warranty terms and workmanship matter more than material alone.

Q5: Can I add Ute accessories later?

Yes, you can, but better if you plan early. Some trays are built with dedicated mounting points and wiring provisions; others require retrofitting. Early planning reduces retrofit costs and avoids weak mounting solutions. If you plan heavy canopies or drawer systems, specify them up front.

Q6: How much does a custom Ute tray cost in Perth?

On average, custom Ute trays cost roughly from $4,500–$10,000 for basic steel trays and $6,500–$15,000+ for aluminium or customised builds. Prices vary by material, size and accessories. As a general guide, steel trays start in the mid-thousands, while aluminium trays can be 20–50% more expensive depending on alloy and finish.