Attachment A AV Spec REV 5.pdf

19AQMMXXAXXXX P0000X

ATTACHMENT A – REV 5.0

23 May 2022

SENSITIVE BUT UNCLASSIFIED

UNITED STATES DEPARTMENT OF STATE

ARMORED VEHICLE SPECIFICATION

19AQMMXXAXXX

i

Revision History

Date Rev. Revision Summary

21 SEP 2016 0.0 Initial Release

23 FEB 2018 1.0 Revised sections B.4, B.6, B.18, B.25, B.26, B.46, B.47, B.52, C.3.6, C.8, C.9.3. Updated language for clarity.

26 JUN 2019 2.0 • Relaxed thickness requirements to allow contractors flexibility in design so long as the vehicle meets all standards.

• Updated Vehicle Types/Tables to reflect current program

Revised tables 1 and 2, and sections B.4, B.7, B.8, B.17, B.28, B.29, B.35, B.39, B.45, B.52, B.58, C.1, C.3.2, C.5.5, C.5.14, C.7.7, C.8.2, C.10, C.15, C.16, C.17. Updated language for clarity.

--APR 2020 3.0 • Re-organized and re-numbered SOW to improve organization and flow

• Added B.2 Definitions Section for Clarity

• Clarification: Contractor-Purchased Base units are considered

Contractor-Furnished Equipment

• Kevlar floor covering (aramid fiber-reinforced plastic laminate layer) is now optional (see section C.4.3)

• Revised sections’ language for clarity (see attached changes chart)

--FEB 2021 4.0 • Removed Chevrolet Suburban 3500

• Removed BMW X5

• Removed Cadillac XTS

• Added references to AWS D1.1

• Added references to DOS AV Inspection Manual

• Revised sections’ language for clarity (see attached changes chart)

16 JULY

4.1 • C.11.1 Updated to clarify trim requirements and unacceptable defects.

• C.11.4 Updated to include .625” tolerance on head room.

• C.12.2 Updated to clarify location of rear strobe

• C.12.3 Updated to require wire loom and shrink tube to aux wiring

• C.12.12 Updated to clarify grounding band location and fastener coating

• C.12.13.1.2 Clarified “automatic mode” for LVD.

• C.12.13.1.2.2 Clarified manual mode.

• C.12.14 Added to specify full operability of driver assistance systems ii

Revision History

Date Rev. Revision Summary

• C.17.4 Moved armored curb height to Inspection 4 and aramid line to inspection 3

• C.19 Added 2 year bumper to bumper warranty.

• D.8 Updated to remove Sprinter 3500

MAY2022

5.0 • Reference Documents Added American Welding Society (AWS) D1.1

• Reference Documents Updated ATPD 2352R to ATPD 2352T

• C.2 Changed delivered fuel level to ¼ tank maximum.

• C.4.1 Removed dual hard reference

• C.4.2 Reduced return clearance for plastic from 20mm to 10mm

• C.4.3 Updated aramid layer requirements

• C.4.4 Added fastener

• C.4.4.5 Added material callout

• C.5.7 Removed material thickness specification

• C.5.8.1, C.5.8.3, C.5.8.4, D.12.2.1, D.12.2.3, D.12.2.4 Changed passthrough dimensions from 1.5x3” to 1.5x4”

• C.5.8.1 Removed “1 ½” diameter access points”

• C.5.8.3 Removed “1 ½” diameter access points”

• C.5.8.4 Removed “1 ½” diameter access points”

• C.5.11 Removed MPI, added “DP90 or similar”, and added top coat language

• C.6 Removed “scratch healing” language

• C.6.4 Added requirements for build prints and supply parts

• C.6.5 Specified what blackout lines on TA should obscure

• C.6.7.1 Changed Windshield and Backlight formatting, subsequent change of Quarter Glass and Swing Door Glass to C.6.7.2

• C.7 Updated swing door language

• C.7.1 Secified functionality of hold-open feature

• C.7.2 Added description of view allowed by rear TA

• C.8.2 Removed section

• C.8.4 Added D1.3 welding requirement

• C.8.4 Added section on MIL-DTL-12560

• C.8.5 Added requirements for PQR for all 2G-4G in all base metal combinations

• C.8.5 Removed section

• C.8.6 Added specification for testing temperature iii

Revision History

Date Rev. Revision Summary

• C.8.7 Replaced HP White with NTS Chesapeake

• C.9.1 Added language to have QA specialist present for 1st article payload. Added GVWR and sticker requirements.

• Figure 1 Specified sum of GAWRs must meet or exceed GVWR

• C.9.2 Added requirements for speed and distance testing of runflats, SAE-J2014 reference

• C.9.4 Specified vehicle suspension performance with added payload

• C.12.6 Added specific operation of AUX 1 switch

• C.12.8 Updated language to include all seating rows

• C.12.8 Updated requirement for dedicated USB charging ports for all seating positions

• C.12.11 Added requirement for circuit protection

• C.12.13.1 Added specific requirements for manual vs automatic modes

• C.12.14 Added requirement for ADAS systems to be calibrated

• C.13.1 Changed verbiage from “hydraulic bottle jack” to “jack”, added requirement to use jack with 2 flat tires

• C.16 Added QA/QC section with specific requirements for OEM and aftermarket part storage.

• C.16.2, C.16.3, C.16.4 Removed cross-reference errors

• C.17 Added lighting requirement for vendor shops

• C.17.1 Removed window tint requirement

• C.17.3 Added references for Inspection 3a guidelines

• C.18.1 Added final inspection requirement for OEM and aftermarket serial numbers

• C.19 increase first article testing to 210 days

• C.19.1 Changed 2,000 miles of endurance testing to 10,000 miles

• C.19.6 Added section for First Article Design Reviews

• D.3.2.1 Changed minimum voltage to 3.2 volts

• D.3.2.1.3 Specified that up idle kit must be active in all transmission modes

• D.8.2.8 Changed verbiage from “bottle jack” to “jack”

• D.12.2.3 Removed 1 ½”circle pass through

• D.12.2.4 Removed 1 ½”circle pass through iv

Revision History

Date Rev. Revision Summary

• D.18.1.1 Added alternator voltage output specification at no greater than 1000 rpm

• D.18.1.1.3 Added 1/0 gauge battery cable requirements v

A. SCOPE

B. APPLICABLE DOCUMENTS AND DEFINITIONS

B.1 Applicable Documents

B.2 Definitions

C. GENERAL ARMORING SPECIFICATIONS

C.1 Base units C.1.1 Government Furnished Vehicles

C.2 Fuel Type C.3 Drive Side

C.4 Opaque Armor C.4.1 Opaque Armor Attachment

C.4.2 Armor Returns

C.4.3 Floor Armor

C.4.4 Door Armor

C.5 Pillar Armor C.5.1 Sail Panels

C.5.2 Wheel Housing

C.5.3 Kick Panels

C.5.4 Toe Board

C.5.5 Roof Armor

C.5.6 Power-train Control Module and Vital Controllers

C.5.7 Pillar/Kickplate Reinforcement

C.5.8 Firewall Pass-through Protection

C.5.9 Vehicle Armor Access Points (Except Group 12)

C.5.10 Camera Mounting Provisions (Except Group 12)

C.5.11 Protective Coating

C.6 Transparent Armor C.6.1 Tinting

C.6.2 Doors

C.6.3 Protection Level

C.6.4 Documentation

C.6.5 Blackout Lines vi

C.6.6 Antennas and Defrosters

C.6.7 Transparent Armor Installation Techniques

C.7 Rear Ballistic Swing Door C.7.1 Swing Door Hold Open Feature

C.7.2 Swing Door Transparent Armor

C.7.3 Swing Door Lock

C.8 Armor Material Quality Control

C.8.1 Sample Testing (Opaque and Transparent Armor)

C.8.2 MIL-DTL-46100E High Hard Steel

C.8.3 MIL-DTL-32332 Ultra High Hard Steel

C.8.4 MIL-DTL-12560 Armor Plate, Steel, Wrought, Homogeneous

C.8.5 Welding Inspection

C.8.6 Transparent Armor (TA)

C.8.7 Change in transparent armor materials (or source of materials)

C.9 Automotive Features and Modifications C.9.1 Payload Requirement and Weight Labeling

C.9.2 Runflat Tires and Wheel Inserts

C.9.3 Upgraded Tires

C.9.4 Suspension

C.9.5 Fuel Tank

C.9.6 A/C Lines, Hoses and Electrical Wiring Harnesses

C.9.7 Operable Windows

C.10 Exterior Vehicle Modifications C.10.1 Body Panels

C.10.2 Door and Pillar Integration

C.10.3 Tailpipe Protection

C.10.4 Door Handles

C.10.5 RAM Bumpers

C.10.6 Roof Racks

C.10.7 Shatter Proof Film vii

C.10.8 Cleanliness

C.11 Interior Vehicle Modifications C.11.1 Trim

C.11.2 Carpet

C.11.3 Heating Ventilation and Air Conditioning

C.11.4 Seat Height

C.11.5 Interior Mirror

C.11.6 Vehicle Locks

C.12 Electrical Features and Modifications

C.12.1 Electrical Connections

C.12.2 PA 650 Button Funtionality

C.12.3 Vehicle Emergency Lights

C.12.4 DriveCam Video Event Recorder Wiring Harness

C.12.5 Battery

C.12.6 Air Bags

C.12.7 Fresh Air Control

C.12.8 Universal Serial Bus (USB) Power

C.12.9 OEM Satellite Communications

C.12.10 Vehicle Siren/PA System

C.12.11 External Battery Connector

C.12.12 Vehicle RF Bonding Grounds (Except Group 12)

C.12.13 Electrical Power Options

C.12.14 Advanced Driver Assistance Systems

C.13 Onboard Equipment and Tools C.13.1 Heavy Duty Jack

C.13.2 Fire Extinguisher

C.14 Automotive Performance Requirements C.14.1 Braking System Performance

C.14.2 Speed and Acceleration

C.14.3 Steering and Handling viii

C.15 Monthly Progress Reports and Meetings C.15.1 Delays

C.16 Quality Assurrance/ Quality Control C.17 Armored Vehicle Quality Assurance Inspections, Test Drive, and Acceptance

C.17.1 Inspection 1 – Base Vehicle Inspection

C.17.2 Inspection 2 – Opaque Armor Fitment Inspection

C.17.3 Inspection 3 – Comprehensive Armor Weldment Inspection

C.17.4 Inspection 4 – Component Reinstallation Inspection and Test Drive

C.17.5 Other Progress Inspections

C.17.6 Excess Material

C.17.7 Acceptance

C.18 Armored Vehicle Documentation C.18.1 Additional Unique Parts and Equipment

C.18.2 Technical Data Package

C.18.3 Manuals

C.18.4 Certifications and Required Documentation

C.19 First Article Approval – Government Testing (FAT) C.19.1 Automotive Testing

C.19.2 Survivability Testing

C.19.3 Remediation During First Article Testing

C.19.4 Failure Reporting, Analysis and Corrective Action System

C.19.5 Configuration Management

C.19.6 First Article Design Reviews

C.20 2 Year Limited Bumper to Bumper Warranty

D. SPECIFIC REQUIREMENTS FOR ARMORED VEHICLES

D.1 GROUP 1 – Reserved D.2 GROUP 2 – Reserved D.3 GROUP 3 – SPORT UTILITY VEHICLE, MEDIUM, Level “C” Armor

D.3.1 Nissan Patrol Fuel Line Protection

D.3.2 Vehicle Power System - OPTION 2 (dual batteries, 12-volt system)

D.3.3 Equipment Mounting Rails ix

D.4 GROUP 4 – Reserved D.5 GROUP 5 – Reserved D.6 GROUP 6 – Reserved

D.7 GROUP 7 – PURSUIT VEHICLE, MEDIUM, Level “C” Armor D.7.1 Floor Armor

D.7.2 Rear Swing Door

D.7.3 Seating Areas

D.7.4 Rear Air Conditioning Unit

D.7.5 Interior Lighting

D.7.6 Trim

D.7.7 Interior Finish

D.7.8 Combat Door Locks

D.7.9 Tailgate

D.7.10 Multi-Purpose Storage Container

D.7.11 Grab Handles and Straps

D.7.12 Weapons Holders

D.7.13 Rear Passenger Windows

D.7.14 Operable Windows

D.7.15 Vehicle Power System - OPTION 2

D.8 GROUP 8 – VAN, LARGE, Level “C” Armor D.8.1 Chevrolet Express

D.8.2 Mercedes/Dodge Sprinter

D.8.3 Vehicle Power System - OPTION 2

D.9 GROUP 9 – Reserved D.10 GROUP 10 – Reserved

D.11 GROUP 11 – Reserved D.12 GROUP 12 - PICKUP TRUCK, STANDARD/COMPACT, Level “C” armor

D.12.1 Headache Rack Removal

D.12.2 Vehicle Armor Access Points, Camera Mounting Provisions and Bonding

D.12.3 Camera Mounting Provisions

D.12.4 Vehicle RF Bonding Grounds x

D.12.5 Vehicle Power System - OPTION 2

D.12.6 Equipment Mounting Rails

D.13 GROUP 13 - Reserved D.14 GROUP 14 - Reserved D.15 GROUP 15 – Reserved

D.16 GROUP 16 – Reserved D.17 GROUP 17 – Reserved

D.18 GROUP 18 – SPORT UTILITY VEHICLE, MEDIUM, LEVEL “D” ARMOR

D.18.1 Vehicle Power System - OPTION 2 (dual batteries, 12 -volt system)

D.18.2 Equipment Mounting Rails

D.19 GROUP 19 –Reserved

SAQMMA16Axxxx P0000x

23 May 2022

A. SCOPE1

This specification describes the requirements for armoring and modifying commercially available passenger vehicles for the U.S. Department of State (DOS). DOS has a recurring need for armored sedans, sport utility vehicles, trucks, vans and replacement parts for these vehicles. DOS armored vehicles are armored to one of three protection levels, “C”, “D”, or “E” level, based on the ballistic resistance and blast resistance of the vehicle. These specifications provide general descriptions of the required armor system design and specifications of acceptable materials to be used. This specification does not specify what thickness of material shall be used in a particular location of the vehicle. The

Contractor is solely responsible for the design of the armored compartment and ensuring the vehicle meets the survivability requirements specified in the Blanket Purchase Agreement (BPA) Call.

Survivability requirements and survivability test requirements are provided in BPA Attachment D

“Armored Vehicle Protection Levels”.

B. APPLICABLE DOCUMENTS AND DEFINITIONS

B.1 Applicable Documents

MIL-DTL-46100E – Detail Specification Armor Plate, Steel, Wrought, High Hardness

MIL-DTL-32332A – Detail Specification Armor Plate, Steel, Wrought, Ultra-High-Hardness

MIL-DTL-12560K – Detail Specification Armor Plate, Steel, Wrought, Homogeneous

MIL-DTL-62474F – Detail Specification Laminate: Aramid-Fabric-Reinforced, Plastic

ATPD 2352T – Purchase Description Transparent Armor

Detailed Test Plan for the Automotive Test of the U.S. Department of State Armored Vehicles

Federal Motor Vehicle Safety Standard (FMVSS) 105

FMVSS 302

Allied Engineering Publication (AEP) 55 Vol. 1 – Procedures for Evaluating the Protection Level of

Armoured Vehicles – Kinetic Energy and Artillery Threat

1 All supplies and services ordered by a BPA Call must first be added to the underlying General Services Administration

(GSA) Federal Supply Schedule (FSS) contract (or consolidated schedule contract) and to the underlying BPA (see clause

I-5 Introduction of New Services/Products).

23 May 2022

AEP 55 Vol. 2 - Procedures for Evaluating the Protection Level of Armoured Vehicles – Mine Threat

49 CFR 567: National Highway Traffic Safety Administration, Department of Transportation;

Certification

MIL-STD-31000B – Department of Defense Standard Practice, Technical Data Packages

MIL-HNBK-2155 – Failure reporting, analysis and corrective action system

MIL-STD-973 - Configuration Management

American Welding Society (AWS) D1.1

American Welding Society (AWS) D1.3

DOS AV Inspection Manual

FAR 52.246-2, “Inspection of Supplies – Fixed Price”

SAE-J2014 - Pneumatic Tire/Wheel/Runflat Assembly Qualifications for Military Tactical Wheeled

Vehicles

B.2 Definitions

Deviation: the action of departing from an established course or accepted standard.

First Article Inspection: is a design verification inspection that confirms the first article was built in accordance to the proposed designs and fabrication methods while meeting the requirements of this specification.

Latent Defect: “Latent defect” means a defect that exists at the time of acceptance but cannot be discovered by a reasonable inspection.

Original Equipment Manufacturer (OEM) Appearance: each vehicle shall maintain a close resemblance in appearance to its original OEM state (as it looked at the time of original purchase).

Production Vehicle: A vehicle which has been armored to the same specifications, design, and build processes as the vehicle which was the approved first article for testing (FAT).

Quality Assurance Inspection: A Government examination of supplies or services (including raw materials, components, and intermediate assemblies) to determine whether they conform to contract requirements and to evaluate whether sufficient progress has been made.

23 May 2022

Showroom Condition: A vehicle in pristine and new condition just off the original equipment manufacturer (OEM) sales floor (i.e. a showroom car would not be covered with salt or mud).

C. GENERAL ARMORING SPECIFICATIONS

Section C contains general armoring specifications that apply to all Department of State armored vehicles unless otherwise specified. Deviations from these general specifications are identified for each vehicle platform in Section D. Armored vehicle platforms and their designated group numbers are also identified in Section D. All welding requirements shall meet active revision of American

Welding Society (AWS) D1.1

C.1 Base units

Base units procured by the contractor for armoring shall be considered Contractor-Furnished

Equipment. The Contractor is required to purchase new, non-defective base units for armoring.

Should the base unit(s) have defects, it is the Contractor’s responsibility to point these out to the

Government Technical monitor (GTM) or Contracting Officer’s Representative (COR) prior to beginning the armoring process. Any correction of latent defects attributed to the OEM or dealership of purchase shall be the responsibility of the Contractor.

The Government shall not assume ownership or liability for vehicles ordered until after final acceptance of the fully armored vehicle. It is recommended that the Contractor thoroughly inspect each base unit prior to purchase. The Contracting Officer may authorize progress payments at the

BPA call level. Progress payment authorization is at the discretion of the Contracting Officer on a case-by-case basis, and is not guaranteed.

C.1.1 Government Furnished Vehicles

The Government may provide unarmored base vehicles as Government Furnished Equipment

(GFE). GFE vehicles and their VINs will be identified at the BPA call level. The Contractor shall provide all personnel and materials necessary to provide and armor all vehicles as specified in the BPA Call. The Contractor shall provide all replacement parts for armored vehicles as specified in the BPA Call. The Contractor is responsible to research the GFE VINs prior to accepting any BPA calls or other work solicited by the Government, and the contractor shall include within its quotation for any GFE armoring orders a suitable amount of time and cost to account for troubleshooting any unanticipated model or trim discrepancies. BPA holders are encouraged to ask questions regarding any GFE prior to quoting or accepting orders for GFE armoring.

C.2 Fuel Type

The fuel type of each vehicle (i.e. leaded, unleaded, dirty diesel, clean diesel) shall be specified in the

23 May 2022

BPA Call. All vehicles shall be delivered with a maximum of a ¼ tank of fuel.

C.3 Drive Side

The drive side of each vehicle shall be specified in the BPA Call. Right hand drive vehicles shall have all operating controls on the right side of the vehicle. Left hand drive vehicles shall have all controls on the left side of the vehicle.

C.4 Opaque Armor

The Contractor shall furnish all opaque and transparent armor materials for the required armored vehicles. Material type and thickness shall meet or exceed all requirements of this specification as well as the classified requirements in BPA Attachment D “Armored Vehicle Protection Levels” to the applicable protection level. Table 1 lists recommended materials for opaque armor applications in the respective locations.

Alternate materials are acceptable in any of the opaque armor locations. Alternate material solutions must be provided to the Government along with supporting ballistic test reports for assessment and shall gain Government approval prior to implementation. The design of alternate material solutions are the responsibility of the Contractor and must meet or exceed the classified requirements in BPA

Attachment D “Armored Vehicle Protection Levels”.

Vehicles produced using alternative materials in any location are subject to first Article Testing per

C.19. No gaps shall be permitted in or between opaque or transparent armor panels. When fabricating the opaque armor system, the Contractor shall use the fewest pieces possible in order to reduce the total number of welds required. The Contractor is to coordinate closely with the COR throughout the armor process.

Table 1. Suitable Materials for Opaque Armor

LOCATION OR

APPLICATION

MATERIAL/ SPECIFICATION

Firewall

Perimeter and Doors

Return Armor

Partition

Roof

Swing door and frame

MIL-DTL-46100E HIGH HARD STEEL

MIL-DTL-32332A ULTRA HIGH HARD STEEL

MIL-DTL-12560K CLASS 2, OR THE MOST CURRENT

VERSION

Floor MIL-DTL-12560K CLASS 2, OR THE MOST CURRENT

VERSION

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The Contractor shall custom armor the complete passenger compartment (360 degrees) in a manner that precludes vulnerability to ballistic penetration as required by BPA Attachment D “Armored

Vehicle Protection Levels” for the applicable protection level and is consistent with the specifications in this BPA Attachment A. All opaque armor shall be formed to the approximate contour of the surface of the vehicle, which shall be the innermost face of the exterior OEM sheet metal of the vehicle. Surface contact between the armor material and the area of installation shall be maintained.

In areas such as “A”,” B”,”C”, “D” pillars and sail panels where surfaces contact cannot be maintained, armor material shall be installed so that there are no ballistic gaps. In some vehicles the contractor may need to securely attach armor to the front fender areas to achieve the maximum ballistic coverage.

C.4.1 Opaque Armor Attachment

The Contractor shall securely attach all opaque armor to interior surfaces of the vehicle body or to other armor. Consistency in attachment techniques shall be maintained throughout the vehicle.

Accessibility of vehicle components shall not be affected by the installation of the opaque armor.

Wherever possible, adjacent armor panels shall be securely attached to each other in order to enhance the overall structural integrity and continuity of the armored compartment. Attachment of opaque armor may be, subject to the other requirements of this BPA, by welding or bolting to the areas involved in such a manner to ensure ballistic integrity. Subassembly weldments of major armor panels may be joined using fastening systems other than welding. The attachment technique employed shall ensure that shifting and/or vibration of the armor materials shall not occur under normal vehicle operating conditions or ballistic impact and that undue residual stress is not placed on the armor that may cause cracking or noise.

Wherever possible, no individual weld shall be less than one inch in length and shall not be spaced closer than one inch to another weld. The contractor may utilize a continuous weld if that is required to provide full ballistic protection within the vehicle. The Contractor may use plug welding as a form of attaching the armor systems, subject to the other requirements of this BPA.

All armor shall be cut by water-jet, laser or plasma cutter.

All butt joints of opaque armor materials meeting on the same plane shall be covered by a four inch wide ballistic backing plate. Where possible, the backing plate shall be welded to the strike side. A backing plate smaller than four inches may be used provided the Contractor demonstrates to the GTM that a four inch plate is not feasible.

Other standard joint designs, (e.g. lapjoints) are also acceptable with COR approval provided their protection is commensurate with the requirements of BPA Attachment D “Armored Vehicle

Protection Levels” for the applicable protection level. The armor shall be fitted to achieve the

23 May 2022 maximum possible coverage of the opaque perimeter of the passenger compartment.

All areas requiring installation of opaque armor not specified herein shall be consistent with the overall level of required armoring (“C”, “D” or “E”) specified in the BPA Call.

C.4.2 Armor Returns

The Contractor shall install opaque armor returns in all door and window openings. The returns shall encircle the door and window openings to the maximum extent possible while allowing the doors to close. The windshield returns shall consist of the roof header, left and right “A” pillar armor, across the entire inner cowl area of the dash, and shall have sufficient overlap necessary to retain the armor integrity during ballistic and blast events. The distance between the return and the glass shall be no more than 7mm. When using a vinyl wrapped door panel, the distance between the return and door panel shall be a minimum of 7mm and a maximum of 10mm return edge to door panel measurement. When using a plastic OEM type door panel, the distance between the return and door panel shall be a minimum of 7mm and a maximum of 10mm.

Contractor shall ensure clearance exists between the finished surface of the return and the door panel. At a minimum, perimeter/return armor must extend far enough into the door opening to cover the bolts used to install the door armor. The sail panel armor adjacent to the foot wells must cover the bolts used to install the door armor. Overlap of opaque and transparent armor shall have sufficient overlap to retain the armor integrity during ballistic and blast events defined in

BPA Attachment D “Armored Vehicle Protection Levels” for the applicable protection level.

C.4.3 Floor Armor

The Contractor shall armor the floor of the vehicle with armor plate that conforms to Military specification MIL-DTL-12560K or the most current version of that standard, with a minimum thickness of .140 inches. The armor plate shall cover the entire floor pan using the fewest number of pieces possible. The floor pan is any surface between the outer edge of the right and left sills of the rocker panels and between the top of the toe board and rear swing door.

After cutting and fitting, the individual armor plates shall be tack welded in place. The floor armor shall be secured to the floor pan in a manner which prevents noise or relative movement.

Butt joint backing plates shall be installed where all armor plates meet on the same plane.

Upon completion of the fitment and tack welding of the floor armor, the COR or a GTM will inspect the installation of the floor armor and provide written approval or disapproval within one business day. Only after approval of the tack welded floor armor shall the floor armor pieces be continuously welded at all joints. Floor armor pieces shall be joined with full penetration welds having a minimum width of 3/16 of an inch. Upon completion of the installation of the steel

23 May 2022 floor armor, an aramid fiber-reinforced plastic laminate layer may be bonded on top of the floor armor.

If an aramid fiber-reinforced plastic laminate layer is installed, it shall be one piece from the front to rear of the vehicle (i.e. shall not overlap in any areas). The aramid fiber-reinforced plastic laminate layer shall be composed of at least 7 plies and shall conform to MIL-DTL-62474F type

2, Class B. After scuffing and cleaning of the floor armor a high strength urethane shall be used to bond the aramid fiber-reinforced plastic laminate panel to the floor armor. Extra care shall be taken at all times during installation of the floor armor materials underneath seating areas to ensure that OEM measurements of distance between the seat and the headliner are maintained.

Also, the installation of the floor armor materials shall not interfere with the OEM specified front and rear movement of the front seats. Extra care shall be taken during installation of the floor armor materials in the gas pedal, firewall and drive train tunnel area.

The Contractor may use a panel of seven layers of laminated FlexPLY aramid/thermoplastic resin pre-preg in lieu of the laminate specified in MIL-DTL-62474F Type 2, Class B, Section 3 requirements, paragraph 3.2.2 Laminating Resin. BPA holders who wish to change the floor armoring material used for their production vehicles (for a previously approved FAT vehicle) must provide a complete floor sample for Government testing and approval prior to changing any production materials. Additional testing shall be coordinated with the COR. Resulting delays may have an adverse impact to delivery and are subject to negotiation.

Floor armoring for vehicles may omit the aramid fiber-reinforced plastic laminate but must provide the equal ballistic protection as specified in BPA Attachment D “Armored Vehicle

Protection Levels.”

Floor armoring for vehicles identified in this specification as “Pursuit”, Sprinter Van or Equal shall not have the aramid fiber-reinforced plastic laminate but must provide the equal ballistic protection as specified in BPA Attachment D “Armored Vehicle Protection Levels.”

C.4.4 Door Armor

The Contractor shall install an opaque armor system to each driver and passenger door. The thickness of material and ballistic coverage shall be sufficient to provide the commensurate level of protection. The door armor system shall not block OEM door drain holes. The Contractor shall ensure that all grinding dust and debris is removed from the door cavity.

All components of the door armor system shall be joined by welding or fasteners so that the weight of the armor system and OEM door is carried by the armor system and is not reliant on the

OEM sheet metal as a load path. The door armor system shall include multiple components as outlined below:

23 May 2022

C.4.4.1 Hinge Side Armor

The contractor shall install armor plate of the appropriate thickness to the hinge side of all door assemblies. The hinge side is the surface of the door skin that generally faces the front of the vehicle and is used as the mounting interface for the door hinges. The hinge side armor shall be welded to or be an integrated part of the hinge mounting point reinforcement. The hinge side armor shall be comprised of as few pieces as possible and provide the maximum ballistic coverage possible.

C.4.4.2 Latch Side Armor

The contractor shall install armor plate of the appropriate thickness to the latch side of all door assemblies. The latch side is the surface of the door skin that generally faces the rear of the vehicle and provides the mounting interface for the door latch. The latch side armor shall be welded to or be an integrated part of the latch reinforcement. The latch side armor shall be comprised of as few pieces as possible and provide the maximum ballistic coverage possible.

C.4.4.3 Outer Door Armor

The contractor shall install .140” MIL-DTL-12560K, or the most current version of that standard, to the inside of the outer OEM door skin. The outer door armor shall use no more than two pieces and cover from the belt line to the bottom of the door by the drain holes. The contractor shall not block the drain holes. If required, the outer door armor shall be formed around the crash bar. The crash bar shall not be moved or removed. If the outer door armor is located inboard of the exterior door handle mechanisms, an access panel shall be installed to maintain ballistic coverage and provide ease of repairs or handle replacement.

C.4.4.4 Ballistic Steel Ring

The Contractor shall install a ballistic steel ring of .187” MIL-DTL-46100E steel which is fastened or welded to the inboard surface of the inner OEM door skin. The ballistic steel ring shall be a monolithic part with no weld joints to complete the ring. The ballistic steel ring shall provide the mounting interface for the inner door armor. A minimum of six bridge pieces shall connect the ballistic steel ring to the outer door armor.

The bridge pieces shall be of equal thickness as the ballistic steel ring and at least two inches in width.

C.4.4.5 Inner Door Armor

The inner door armor shall be a one piece panel of High Hard 46100 or Ultra High Hard

32332A that provides the maximum ballistic coverage possible yet allows for operation of all

23 May 2022 required mechanisms. The inner door armor shall be attached to the ballistic ring with M10, Class 10.9 bolts. The bolts shall be spaced no more than four inches apart where possible.

Perimeter / return armor will need to extend far enough into the vehicle to cover door armor bolts.

C.5 Pillar Armor

The Contractor shall armor the “A” pillars from the front roof header to the floor sill plate. All other pillars shall be covered fully from the roof to the floor. In areas where transparent and opaque materials do not meet on the same plane and surface contact cannot be maintained, opaque armor returns shall be installed as filler so there are no ballistic gaps. Returns shall be installed perpendicular to the plane of the primary armor. Returns shall be fitted on all pillars to provide ballistic coverage from oblique projectile trajectories impacting at the door to pillar seam. Sail

Panels

C.5.1 Sail Panels

Approved perimeter armor shall be used in the sail panel areas. Sail panel armor shall provide coverage from roof header to package shelf and from the backlight to the door or quarter glass, as applicable. The steel shall overlap adjacent transparent armor sufficiently to retain the armor integrity during ballistic and blast events.

C.5.2 Wheel Housing

The Contractor shall install opaque armoring materials over the right and left wheel housing areas where these areas intrude into the passenger compartment of the vehicle. The Contractor shall incorporate the fewest possible number of pieces into assembling the wheel housing area.

C.5.3 Kick Panels

The Contractor shall install opaque armoring materials inside the right and left upper and lower kick panels.

C.5.4 Toe Board

The Contractor shall install opaque armoring materials inside the left and right front toe board from the flat of the floor board to the firewall as high as practical.

The Contractor shall install the armoring in a manner that does not interfere with the free travel of the clutch (if equipped), brake or accelerator pedals.

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C.5.5 Roof Armor

The Contractor shall install opaque roof armor inside the entire roof area, utilizing the fewest number of pieces possible. Roof armor shall cover from the windshield header to the rear window and between the left and right roof rails.

At the point where the roof armor transitions into the windshield area, the roof armor shall be installed under the opaque armor that extends from the windshield to the roof. Alternatively, a backing plate may be installed over the joint where the windshield header meets the roof armor.

If the vehicle is equipped with a sunroof, the sunroof shall be removed from the vehicle and replaced with a 20-gauge piece of sheet metal, and repaired per Section C.10 “Exterior Vehicle

Modifications”.

C.5.6 Power-train Control Module and Vital Controllers

Subject to approval by the COR, the Contractor shall protect all vital vehicle control modules or systems to ensure continued vehicle operability during a ballistic or blast event as anticipated by

BPA Attachment D “Armored Vehicle Protection Levels” for the applicable protection level.

This may require complete or partial armoring of the front fenders. The Contractor shall fabricate and install armor around the electrical center (with top). All additional wire entry points shall be covered where possible using a Contractor designed armor system. All wire entry point designs shall be inspected by the GTM and approved by the COR.

C.5.7 Pillar/Kickplate Reinforcement

The Contractor shall install inner kick-plate and pillar reinforcements in the “B” and “C” Pillars.

Pillar and kick-plate reinforcements are structures located between the outer skin of the OEM sheet metal and the armor panels to integrate the armor protection to the OEM vehicles’ structure and stiffen the pillars. They support the armor panels and help cover ballistic angles the armor panels might not be able to cover themselves.

All pillar and kick-plate reinforcement structures shall be designed and fabricated such that the assembly will have the same strength and stiffness as a one piece structural member of similar cross section. Reinforcement assemblies shall have robust joint design and sufficient weld or fasteners to provide the same strength and stiffness as a one piece structural member of similar cross section.

C.5.7.1 Inner Kick-Plater Reinforcement

A “U” channel reinforcement structure shall be built behind each kick-plate armor panel to support it and help its ballistic protection integrity. The “U” channel structure shall be used to anchor the front door hinges and provide ballistic protection for wiring harnesses, pass-

23 May 2022 through holes and fuse boxes.

C.5.7.2 “B” Pillar Reinforcement

A “U” channel reinforcement structure shall be built behind each “B” pillar armor panel(s) to provide stiffness and increase its ballistic integrity. The “U” channel reinforcement structure shall be used to anchor the rear door hinges and provide ballistic protection for wiring harnesses, pass-through holes, seat belts and seat belt anchor points.

Where structurally permitted, the legs of the “U” reinforcement (Plates located perpendicular to the “B” pillar) shall be mechanically restrained (e.g. welded) by the floor armor of the vehicle at the bottom and by the roof armor of the vehicle at the top.

C.5.7.3 “C” Pillar Reinforcement

The C Pillar “U” channel reinforcement structure depends on the vehicle type. Some vehicles allow U channel reinforcements, others only allow one reinforcement channel and others do not allow any reinforcement. “U” channel reinforcements will be specified in the BPA Call.

The Contractor shall, at no additional cost to the Government, provide “U” channel reinforcements to the maximum extent possible based on vehicle type and subject to the requirements of the BPA Call.

The “U” channel reinforcement structure serves to provide ballistic protection for wiring harnesses, pass-through holes, seat belts and seat belt anchor points. Where structurally permitted, the legs of the “U” channel reinforcement shall be mechanically restrained (e.g.

welded) to the floor and to the roof.

(For Group 8 vehicles only, “U” channel reinforcement is built behind the armor panel(s) and spaced evenly from the “C” pillar of the rear door to the “D” pillar or the swing door armor frame.)

C.5.7.4 No Reinforcement

In the case where the vehicle will not allow for any “U” channel reinforcement on the “C” pillars, the backrest protection plates shall work as a beam between the left and right “C” pillars. The backrest plates shall be attached to the vehicles floor armor at the bottom and to the roof armor at the top.

C.5.8 Firewall Pass-through Protection

All wiring harnesses, HVAC and cables passing through the firewall from the engine

23 May 2022 compartment shall be protected by MIL-DTL-46100E steel. The design and the placement of the pass through shall not interfere with the installation of the dashboard, heater box and ducts. The contractor shall securely attach all opaque armor to the firewall surfaces of the vehicle to achieve the maximum possible coverage. The firewall pieces shall be continuously welded at all connection joints. No backing plates are required. Armor plating installed in the area of the brake booster mounting studs of the firewall shall not interfere with application of the brakes. The contractor shall coordinate closely with the COR or GTM throughout the armor process in this area.

C.5.9 Vehicle Armor Access Points (Except Group 12)

C.5.9.1 Firewall Access Points

The vehicle shall have access points through the vehicle armor to the engine compartment on both the driver and passenger sides conforming to the requirements of Section C.5.8

“Firewall Pass – Through Protection”. These access points will be used to pull additional cabling from the interior of the vehicle to various engine bay components. These access points shall be 1 ½”x4” rectangles. If access points in these locations already exist that are of equal size or larger, they may be used as long as OEM vehicle wiring does not utilize more than half of the available area.

C.5.9.2 Roof Access Points

The vehicle shall have four access points through the vehicle armor leading to the vehicle roof. The OEM vehicle roof does not require an access point to be placed through it, only the armor. The access points shall have armored access covers that shall extend at least 1” past the opening of the access points. These covers shall be unbolted and removed from the interior of the vehicle. The access covers shall be able to have a ¾” spacer placed between them to allow Radio Frequency Connectors (RF cables) to be routed out the access point from the interior side of the vehicle. The 3/4” spacer shall not disrupt the fitment of the vehicle headliner.

RF cables, installed by the Government after armoring process shall be primarily routed up the A, B, C, and D pillars of the vehicle and routed between the head liner and armor of the vehicle. The vehicle headliner shall not interfere with the routing of cables out of the access points.

C.5.9.2.1 Forward Roof Access Points

One access point shall be approximately 5 inches forward of the B Pillar and shall be a 1

½” x 4” rectangle. The access point shall be placed in the longitudinal center line of the vehicle. This access point shall provide access to the vehicle roof forward of this location

23 May 2022 free from obstruction by OEM roof reinforcements. The access point can be moved forward or back 3” (relative to the front of the vehicle). Access point may be moved toward the driver side of the vehicle if required because of the design of the vehicle’s roof. This access point shall be easily accessible after dropping the vehicle head liner.

C.5.9.2.2 Middle Roof Access Points

One access point shall be centered between the C and D pillars of the vehicle, and shall be a 1 ½” x 4” Rectangle with the long dimension running to the front of the vehicle. The access point can be moved forward or back 9” (relative to the front of the vehicle) but not side to side. If an access point is already called for by another system requirement in this general area, this access point can be used instead, so long as it meets or exceeds the dimensions listed above. Access point may be moved toward the driver side of the vehicle if required because of the design of the vehicle’s roof. This access point shall be easily accessible after dropping the vehicle head liner.

C.5.9.2.3 Rear Roof Access Points

Two access points shall be symmetrically placed in the rear corners of the vehicle roof armor and shall be 1 ½” x 4” Rectangle with the long dimension running to the front of the vehicle. These access points shall be approximately 4” from the interior side of the swing door frame and 7” from each side of the exterior vehicle roof. These access points can be moved up to +/- 3” in either direction for ease of placement, so long as these access points remain symmetrical on the vehicle. These access points shall be easily accessible after dropping the vehicle head liner.

C.5.9.3 Underbody Access Points

The vehicle shall have access points through the vehicle armor leading to the underside of the vehicle. These access points through the armor shall be located at each rear corner of the interior floor of the vehicle, and shall be a 1 ½” x4” rectangle. These access panels shall be easily accessible after removing vehicle trim and/or carpet. The exit of the access point under the vehicle shall be easily accessible.

The access points shall have armored covers that will extend at least 1/2” past the opening of the access points. These covers shall be removable from the interior of the vehicle.

C.5.9.4 Rear Wall Access Points

The vehicle shall have two access points in the vehicle armor that leading through the rear vehicle wall on either side of the rear door. These access points through the armor shall be located near the floor of the interior of the vehicle and shall be a 1 ½” x4” rectangle. These

23 May 2022 access points shall be easily accessible after removing vehicle trim and/or carpet. These access points shall be easily accessible from the exterior of the vehicle after opening the rear door and/or removing rear door vehicle trim. The access points shall have armored covers that shall extend at least ½” past the opening of the access points. These covers shall be removable from the interior of the vehicle.

C.5.10 Camera Mounting Provisions (Except Group 12)

Each vehicle shall have provisions for mounting cameras that look in all directions. Mounting provisions shall be lengths of top hat shaped 16 gage steel that provide a 2.5-inch-wide surface and 0.75-inch standoff from the interior armor surface. The locations of required top hats are outlined below:

C.5.10.1 Front Windshield

The vehicle shall have at least a four-inch length of top hat centered above the windshield within four inches of the trimmed opening.

C.5.10.2 Driver and Passenger Doors

Each door shall have roughly horizontal top hat channel above at least the rear-most four inches of the trimmed opening.

C.5.10.3 Rear Quarter Side Windows

Each rear quarter side window shall have a length of top hat above and below the trimmed opening mounted between three inches and seven inches from the trimmed opening. Each top hat shall extend at least two inches on either side of the center of the window opening, and be at least seven inches long.

C.5.11 Protective Coating

All surfaces of all opaque armor panels (after heat treat, where applicable) shall be coated with a corrosion-resistant material, such as DP90 or similar epoxy primer, in a manner which will ensure a smooth surface and should be top coated according to primer manufacturer specifications. Contractor shall coat the armor that is against the factory sheet metal before it is installed. Any area of armor where the coating is affected by the weld process and is accessible after installation shall be recoated.

C.6 Transparent Armor

All standard OEM glazing’s (with the exception of cargo doors / tailgate) are to be removed from the vehicles and replaced with curved, transparent armor. All materials shall be free of dirt, scratches, 23 May 2022 abrasions and nicks as specified in ATPD-2352T section 4.2.3 allowable defects and installed in the most unobtrusive manner possible. Glazing with irregularities which distort the driver’s vision or provide a hindrance to the safe operation of the vehicle will not be accepted. All transparent armor and its installation methods are subject to the approval of the CO/COR prior to installation in the vehicle.

C.6.1 Tinting

Tinting on any transparent armor visible from the exterior of the vehicle shall match the color and light transmission of the OEM glass that it replaces. Any tinting on the transparent armor will be identified in the BPA Call.

C.6.2 Doors

Front driver side transparent armor and front passenger side transparent armor on all vehicles, as well as transparent armor on both rear doors other than vans, shall fill the maximum amount of the OEM opening. All door transparent armor shall be squared edged and installed in a U-channel with sufficient overlap necessary to retain the armor integrity during ballistic and blast events defined by BPA Attachment D “Armored Vehicle Protection Levels” for the applicable protection level. Transparent armor dimensions for specific vehicles can be found in their respective location in Section D. The “U” channel shall be welded or bolted in place and powder coated or painted to maintain OEM appearance. It shall have a “U” style bracket attached with urethane to the bottom of the transparent armor, which shall be held in place by two height-adjustable brackets that shall be bolted to the inner door armor beneath the transparent armor using 4 M10 Hex Head, Class 10.9 bolts per bracket. The brackets shall provide an L-shaped support to the transparent armor that overlaps by at least the amount of the U-channel.

C.6.3 Protection Level

Transparent armor material type and thickness shall meet or exceed the requirements of this section and the classified requirements in BPA Attachment D “Armored Vehicle Protection

Levels” applicable to each protection level. Upon inspection, the COR may require the contractor to ship any transparent armor component to a designated laboratory for optical quality testing. Prior to sending transparent armor components to a designated laboratory for optical quality testing, the Contractor shall obtain written approval from the CO.

C.6.4 Documentation

Upon final inspection of first article and each production asset, as specified in the BPA Call

Award, the Contractor shall provide to the COR a bill of materials for the transparent armor and a copy of the build prints for each piece of transparent armor installed in the vehicle. The bill of materials shall note the armorer’s production number, vehicle identification Number (VIN), 23 May 2022 glass manufacturer, glass manufacturer part number, glass serial number and where in the vehicle each piece of transparent armor is installed.The build prints must be production level, fully describing the geometry and dimensions of each piece of transparent armor.

C.6.5 Blackout Lines

The transparent armor blackout lines shall not interfere with driver or passenger visibility including the outside rear view mirrors. The transparent armor blackout lines must obscure the line of sight to any opaque armor when viewed from either the interior or exterior of the vehicle.

C.6.6 Antennas and Defrosters

If OEM glass with antennas or defrosters is removed and replaced with transparent armor, antennas or defrosters shall be installed in the transparent armor. If OEM quarter glass is reinstalled, any second antenna should not be required in the transparent armor. The exterior profile of the overlap shall be minimized to retain OEM appearance while remaining large enough to ensure acceptable armor performance. Warranty under C.19 shall cover any defects, damages, or other issues that may arise with the installation or the manufacture of the transparent armor and the glass itself, to include a warranty on the seal and the other parts that are used in the installation.

C.6.7 Transparent Armor Installation Techniques

All transparent armor installed shall be tested for water leaks and shall not allow water into the vehicle.

C.6.7.1 Windshield and Backlight.

The stationary windshield and backlight shall be installed according to normal automotive glazing practices, as long as the installation materials conform to the armored glass manufacturers recommendations and do not contain toluene, methylene chloride, or components that have silicone as a base component. The windshield and backlight shall sit on urethane and shall not be allowed to rest on the vehicles pinch welds. The windshield and backlight shall include a mechanical restraint system to restrain the windshield during blast events. The windshield restraint system shall mount to a fixed position on the “A” Pillar armor. The Contractor shall install two mounting brackets, one on the lower left and one on the lower right bottom of the windshield to assist with windshield replacement. Brackets shall be large enough to support the windshield and not interfere with the OEM appearance of the vehicle. The backlight restraint system shall mount to a fixed position on the rear most pillar.

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C.6.7.2 Quarter Glass and Swing Door Glass

Quarter windows shall be installed either through the “D” pillar or installed from the outside with the OEM glass reinstalled over the ballistic window. With the exception of transparent armor installed through the D pillar, all square-edged quarter glass that is installed behind

OEM glass shall be installed on the…