SOW.docx

Updated 16 SEP 2015

Section C - DESCRIPTION/SPECIFICATIONS/STATEMENT OF WORK

Objective: To procure and armor Cadillac DTS vehicles. Vehicles acquired thru this acquisition shall be armored to Level “C” as indicated in Table 1 below:

Table 1 - Approved Armoring Materials

Table 1 – Armoring levels for transparent and opaque armor

Specifications:

Fuel: All vehicles shall be delivered with a minimum of a ¼ tank of fuel.

Armor Materials/Processing: The contractor shall properly heat-treat all ferrous armor if required. No gaps shall be permitted in or between armor material panels or transparencies. All butt joints of all opaque armor materials meeting on the same plane will be overlapped or butt plated. All butt joints of all opaque armor panels meeting at any angle will be overlapped or butt plated, as required, to meet ballistic specifications. When fabricating or applying the opaque armor (OP) system, the contractor shall manufacturer the largest piece’s available for that area of installation, to reduce the total number of welds required.

Certified Welding Inspector: The Contractor shall employ a Certified Welding Inspector (CWI) certified to D1.1 (Structural steel 2010 edition) who carries a valid AWS number and stamp. The CWI must hold a valid DoD secret level security clearance. The CWI will maintain the Welding procedure specifications (WPS); the procedure qualification record (PQR) including base metal, filler metals, processes and techniques and welder personal qualification.

Hardness Testing and Samples: Any ferrous opaque armor materials used in the armoring process shall require certification of hardness. The contractor shall conduct a hardness test on a minimum of twenty (20) percent of these materials, and submit a copy of the test results to the CO for verification and quality audit. Any composite armor material used in the armoring process shall require certification through inspection and testing. The contractor shall radio graphically (or by other pre-approved method) inspect a minimum of twenty (20) percent of any composite armor parts from each batch for verification and quality audit. The Contractor shall furnish the identification of those vehicles armored under the tested lots/batches of either steel or composite. All material shall be inspected a minimum of twenty (20) percent of the defined lot. The twenty (20) percent required for testing shall be drawn from each type of armor material used in the vehicle. A report of the test results shall be included in the inspection report and shall indicate the type tests performed on all material.

The Contractor shall submit to an independent testing laboratory (HP White, UDRI) opaque armor samples for each armored vehicle at no additional cost to the Government to test the ballistic performance and defeat capability according to DOS specifications. These samples shall be fifteen (15”) inches by fifteen (15”) inches. One (1) sample per lot of Opaque material used, for a maximum. The sample shall be identified with the vehicle build number permanently stamped onto the armor. For steel, the contractor shall provide Rockwell c test results, in other materials, the appropriate test information for the samples will be provided to the CO. Transparency samples will be required with the introduction of a new glass cross section or company. Transparency samples shall be submitted to an independent testing laboratory (HP White, UDRI) at no additional cost to the government. Copy of all test results will be provided to the CO. Results of DOS testing will be shared with the performing contractor(s) at the discretion of the CO.

Protective Coating: Front and rear surfaces of all ferrous opaque armor (after heat treat, where applicable) panels shall be coated with a corrosion-resistant material by the contractor, in a manner which will ensure a smooth surface.

Opaque Armor: The contractor shall custom armor the complete passenger compartment (360 Degrees) in a matter, which shall preclude vulnerability to ballistic penetration. All opaque armor will be formed to the approximate contour of the surface of the vehicle, which shall be the inner skin of the vehicle wherever possible and where feasible, 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.

Approved Opaque Armoring Materials

Level C:

MIL-A-46100 HIGH HARD STEEL .187 INCH Firewall

MIL-A-46100 HIGH HARD STEEL .187 INCH Perimeter

MIL-A-46177B (or the most current version) HIGH HARD STEEL .140 INCH Floor

MIL-A-46100 HIGH HARD STEEL .187 INCH Roof

MIL-A-46100 HIGH HARD STEEL .3125 INCH Swing door and frame

Level D:

MIL-A-46099 DUALHARD STEEL .275 INCH Perimeter

MIL-A-46100 HIGH HARD STEEL .405 INCH Perimeter, swing door and frame

MIL-A-46100 HIGH HARD STEEL .375 INCH Roof

MIL-A-46177B (or the most current version) HIGH HARD STEEL .140 INCH Floor

Other Armor: Subject to CO approval, the contractor may use material other than those identified above. Prior to CO approval the contractor must submit samples for testing to substantiate the materials performance in this application.

Forming of Opaque Armor: All opaque armor shall be formed to the contour of the surface of the application, which will be inside the outer skin of the vehicle, whenever possible, and unless otherwise designated herein. Where feasible, surface contact between armor material and the area of installation will be maintained.

Opaque Armor Attachment: All opaque armor shall be securely attached to interior surfaces of the vehicle body. The Government will review and approve the attachment techniques (Consistency in attachment techniques shall be maintained in vehicle from front to rear and side to side). Accessibility of vehicle components shall not be affected by the installation of the opaque armor. Wherever possible, adjacent armor panels and areas 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 by welding as appropriate to the areas involved and in such a manner so as to ensure ballistic integrity. The attachment technique employed shall ensure that shifting and/or vibration of the armor materials will not occur under normal vehicle operating conditions or ballistic impact and that undue stress is not placed on the armor that may cause cracking or noise. Where the armor attachment is by welding, it shall be the contractor’s responsibility to demonstrate that the heat-affected zone does not reduce the defeat capabilities of any ferrous armor. At no time shall an individual weld exceed one inch (25.4 mm) in length and shall not be spaced closer than 2 inches (50.8-mm) to another weld. The contractor can also use plug welding as a form of attaching the armor to the vehicle. All armor attachment methods must receive written approval from the CO prior to being used. All armor shall be cut by water-jet, laser or plasma cutter so as to eliminate the possibility of weakened stress points and cracks. The Contractor shall install all armoring materials so that butt joints or seams will be overlapped or butt-plated and installed on the strike side. The contractor shall cover with sewn padded vinyl all opaque armoring materials not concealed by OEM trim and match the color of the vinyl to the inside of the vehicle. The armoring material shall be installed, not only to allow controlled ballistic expansion resulting from projectiles impacting on armored material, but also to prevent dislodgment in the event of a ballistic attack. The armor shall be fitted so as to achieve the maximum possible coverage of the opaque perimeter of the passenger compartment.

Armor Returns: The contractor shall install opaque armor returns in all door and window openings. The returns will encircle the door and window openings. The windshield returns will consist of the roof header, left and right “A” pillar armor and across the entire inner cowl area of the dash. The distance between the return and the glass/armor shall be between 7 to 10 mm.

Floor Armor: The floor of the vehicle shall be covered with armor plate that conforms to Military specification MIL-A-46177B (or the most current version) with a minimum thickness of .140 inches (355MM). The armor plate shall cover the entire floor pan (minimum amount of pieces as possible will be used). The entire floor pan means from the outer edge of both right and left sills of the rocker panels, to the top of the toe board and terminates at a point no less than two inches underneath the rear seat high level armor or rear swing door. After cutting and fitting, the individual armor plates will be laid in place and tack welded to the floor pan of the vehicle. The floor armor pieces will be continuously welded at the connection joints. The floor armor shall be secured to the floor pan in a manner which prevents noise during its relative movement. Butt-plates will be installed by a certified welder were all armor plates have a seam. This manner shall be subject to government approval. Upon completion of the tack welding of the floor armor, a DOS inspector will inspect the installation of the armor plate. After approval from the inspector, final welding of the floor armor system will take place. AWS Certified welders will MIG weld all floor armor joints and seams using previously described equipment and materials. The weld bead will have a minimum width of 3/16 of an inch and extend no less than 1/16 of an inch above the surface of the armor plates. Upon completion of the installation of the steel floor armor, a panel of seven (7) layers of laminated Kevlar will be bonded on top of the floor armor. This seven (7) Kevlar laminate shall conform to MIL-PRF-61474-C type 2 class B with exception that the minimum pressure is seven (7) PSI. After scuffing and cleaning of the floor armor a high strength urethane will be used to bond the Kevlar panel to the floor armor. Extra care will be taken at all times during installation of the floor armor materials underneath seating areas to ensure that OE measurements of distance between the seat and the headliner will be maintained. Also, the installation of the floor armor materials shall not interfere with the OE specified front and rear movement of the front seats.

Door Armor: Opaque armor shall be installed on the front side of all doors (hinge side) and the rear side (latch side). The door latch area shall be reinforced with Opaque armor. The door will consist of a dual layer armor system. The system will consist of two pieces of 9/64 MIL-A-46177 steel attached to the outer skin of the door at the belt line and at the bottom by the drain holes. The drain holes must remain open (DO NOT BLOCK THE DRAIN HOLES). The hinge side piece will be welded to the hinge reinforcement. The latch side will be welded to the latch reinforcement. An access panel will be affixed to the latch side of the armor to cover door handle opening to provide for ease of repairs or handle replacement. A ballistic steel ring will be fabricated from 3/16 MIL-A-46100 steel by the contractor and welded to the inner door skin. A minimum of six (6) bridge pieces will connect the outer skin armor to the ballistic ring. The inner door 3/16/.405/.275 dual hard will be attached to the ballistic ring with a minimum Twelve (12) grade L9 bolts, depending on the size of the door. The bolts will be spaced no more than 4” apart. Any changes to this dual layer system must be approved by the CO prior to installation. The contractor must submit the changes to the dual layer armor system design to the CO for approval ten (10) working prior to date of receipt.

Pillar Armor: The “A” pillars shall be armored 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 material shall be installed as filler so that there are no ballistic gaps. These pillar armor components may require installation perpendicular to the plane of the primary armor (Splash Guards/Returns). The purpose is to preclude the intrusion angles of ballistic attack when the planes of the transparent and opaque armor overlap. Transparent armor adjacent to the pillar armor shall be overlapped a minimum of three (3) inches or to the edge of the blackout line on the transparent armor. The opaque armor shall be fitted on all pillars in a manner to preclude all angle shots.

Sail Panels: Only Approved Dual Hard Steel (DHS) or monolithic steel MIL-A- 46099 or MIL-A-46100 shall be used in the sail panel area. 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 by two (2”) inches.

Rear Seat back: The contractor shall install Approved armoring materials behind the upright portion of the rear seat on all sedans. This material shall extend from the floor pan to the rear window package shelf and the width of the vehicle, so that it shall butt the armor installed in the quarter panels and/or wheel housing areas without impeding the re-installation of all OEM materials, including equipment or trim covering.

Rear Package Shelf: The contractor will fit approved armoring materials on the rear package shelf against the rear seat back and right and left sail panels.

Wheel Housing: The Contractor shall install approved armoring materials over the right and left wheel housing areas where these areas intrude into the passenger compartment of the vehicle. The least amount of pieces will be incorporated into assembling the wheel housing area.

Kick Panels: The Contractor shall install approved armoring materials inside the right and left upper and lower kick panels.

Toe Board: The contractor shall install approved 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 such a manner, so that it does not interfere with the free travel of the clutch (if equipped), brake or accelerator pedals.

Roof Armor: The contractor shall install approved roof armor inside the entire roof area, utilizing the least number of pieces, from windshield header to rear window and fully between the left and right roof rails. If the vehicle is equipped with a sunroof, the sunroof shall be removed from the vehicle. In the event of a transparent sunroof panel, the panel shall be removed and a 20 gauge piece of sheet metal blank made will be designed and installed in the opening in such a manner that lends a pleasing appearance form outside the vehicle. This design must be approved by the CO before installation.

Undefined Areas: The contractor shall mount the approved armoring materials inside all interior opaque vertical surfaces .

Pillar/Kick Plate Reinforcement: The contractor shall fabricate for 3/16 MIL-A-46100 High Hard steel and install inner kick-plate and pillar reinforcements in the “B” and “C” Pillars. Pillar and kick-plate reinforcements are structures located between the OEM sheet metal outer skin and the armor panels to integrate the armor protection to the OEM vehicles’ structure. They also help armor panels stay in place in case of an external explosion and to help cover ballistic angles the armor panels might not be able to cover themselves.

The Pillar kick plate reinforcements work as a backbone, as the load bearing structure that helps to keep the armor panels on its original position without collapsing in the event of a threat. The pillar and kick-plate reinforcements are to be installed in between the OEM outer vehicle’s cabin that protects the pillars and the inner kick-plate area.

All pillar and kick-plate reinforcement structures will be lightened up by removing excess material. The material reduction should be at least 20% of its original weight. Once the pillar and kick-plate reinforcements are lightened, they will become truss like structures instead of solid beams.

The material reduction will not compromise the ballistic protection or the rigidity of the armor panel is reinforcing. The right ballistic protection can be achieved by: enclosing the armor panel opening with armor plates behind it, placing an armor backing plate behind the armor panel opening, or a combination of both. The size of the armor backing plate will depend on the distance between the backing plate and the armor panel.

Inner Kick-Plate Reinforcement: A C type channel structure (C Reinforcement) is built behind the kick-plate armor panel (S) to support it and help its ballistic protection integrity. The C reinforcement structure is used to anchor the front door hinges and it also serves as a ballistic protection covering wiring harness pass-through holes and fuse boxes if applicable.

“A” Pillar: Not Applicable

“B” Pillar: A C reinforcement will be built behind the “B” pillar armor panel(S) to support and help its ballistic protection integrity. The C reinforcement structure is used to anchor the rear door hinges and it also serves as a ballistic protection covering wire harness pass through holes, seat belt and seat belt anchor points.

The legs of the C reinforcement (Plates located perpendicular to the “B” pillar) will be mechanically restrained by the floor protection of the vehicle at the bottom and by the roof protection of the vehicle at the top. This will improve the vehicles blast protection performance.

“C” Pillar: The “C” pillar reinforcement depends on the vehicle type. Some vehicles allow C reinforcements, others only allow one beam reinforcement and others do not allow any reinforcement.

A C reinforcement is built behind the “C” pillar armor panel(s), between the rear door and the quarter glass opening. It supports and helps the C pillar ballistic protection and integrity. The C reinforcement structure serves as a ballistic protection covering wire harness pass through holes, seat belt and seat belt anchor points. The legs of the C reinforcement (Plates located perpendicular to the “B” pillar) will be mechanically restrained by the wheel well protection at the bottom and by the roof protection of the vehicle at the top. This will improve the vehicle’s blast performance.

Beam Reinforcement: Beam reinforcement is a plate perpendicular to the “C” pillar that is placed between the rear door and the quarter glass opening. The beam is intended to maintain the armor “C” pillar plate(S) in place against an external blast. The beam will be mechanically restrained by the wheel-well protection of the vehicle at the bottom and by the roof protection at the top. This will improve the vehicles blast protection performance.

No Reinforcement: In the case where the vehicle will not allow for any reinforcement on the “C” pillars, the backrest protection plates will work as a beam between the left and right “C: pillars. The backrest plates will be attached to the vehicles floor protection at the bottom and to the roof protection at the top. This will improve the vehicles blast protection performance.

Firewall pass-through protection: All wiring harnesses, HVAC and cables passing through the firewall, from the engine compartment shall be protected by 3/16 Mil – 46100 steel dog house fabricated and installed by the contractor to preclude ballistic penetration, The design and the placement of the dog house shall not interfere with the installation of the dashboard, heater box and ducts. The design and placement of the doghouse shall be approved by the CO prior to installation.

Approved Transparent Materials: The following transparent armor (Types and thickness) meet both ballistic and optical quality standards and are authorized for use.

GKN Model PA330 33.0mm (1.32 inch)

AGP Model B894-1-LC 33.0 mm (1.32 inch)

Oran 33.0 mm (1.32 inch)

O’Gara 33.0 mm (1.32 inch)

All other types and models of transparent armor shall be tested both ballistically and optically.

Transparent Armor: All standard OEM glazing’s are to be removed from the vehicles and replaced with curved transparent armor fabricated with flat edge or a rebated edge for the doors. All transparent armor will have a scratch healing urethane liner or equivalent unless the individual delivery order deletes that requirement to transparent armor at no additional charge to the Government. All materials shall be free of dirt, scratches, abrasions and nicks and shall be installed in the most unobtrusive manner possible. All transparent armor and its installation is subject to the approval of the CO prior to installation in the vehicle.

The contractor shall provide to the Government a copy of the build prints for each piece of ballistic glass installed in the vehicle. The list will note the armorer’s production number, vehicle identification Number (VIN), glass manufacturer, glass serial number and where in the vehicle each piece of glass is installed.

The transparent armor area shall fill the maximum amount of the OEM opening. The transparent armor blackout lines shall not interfere with view of the outside rear view mirrors. Any OEM antennas or defrosters shall be installed in the transparent armor. Any tinting on the glass will be determined by the CO or their representative. All door transparent armor will be squared edged and installed in a U-channel with a 1 1/2 inch overlap.

Glazing Techniques: The contractor shall install all transparent armor by using a urethane sealer. The transparent armor must sit on urethane and will not be allowed to rest on the vehicles pinch weld. The stationary windshield and back window will be installed according to the normal automotive glazing practices, as long as the installation materials conform to the armored glass manufacturers recommendations and do not contain toluene, methylene chloride, etc. which have silicone as a base component. The Windshield and backlight will also be installed with Kevlar straps mounted to a fixed position on the “A” Pillar and the “C” pillar. All glass installed will be tested for water leaks and shall not allow water into the vehicle.

Use of other Opaque and Transparent materials: If the contractor proposes to use any opaque or transparent armoring materials not specified above, the armor shall be tested by H.P> White Laboratory Inc. 3114 Scaraboro Street, Maryland 21154 or other approved independent laboratory. Contractors desiring to use armoring materials not specified herein must have the laboratory testing done at their own expense prior to contract award and have the results submitted to the contracting officer. The contractor shall submit the design and the laboratory results to the CO for written approval before use of the proposed transparent or opaque armor, The optical quality standards test for transparent armoring materials shall include the angle of installation of the armor, which side(S) is to be masked, exact areas to be masked and the type of materials to be used for masking.

OEM Glass: Any original equipment glass not replaced by multi-layer glass transparencies will be covered with a 3m type window film. The decision on whether this film is to be tinted or clear will be made by the CO.

Electrical Connections: The contractor when installing or modifying any electrical wiring in the vehicle shall solder and heat shrink all electrical terminal connectors.

Unique Parts: The contractor shall furnish the U.S. Department of State a listing, by part number, serial number (when available), and supplier, of all contractor-furnished unique parts and/or equipment installed in and/or upon this vehicle.

Drawings, Schematics, etc.: The contractor shall produce and provide any and all drawings, schematics, templates, and check fixtures necessary for the production and/or application of other than original equipment (OE) installations made in or upon this vehicle. The contractor shall provide to the CO and the transparent armor manufacturers, all drawings to ensure that all transparencies fit properly.

Service and Parts Manuals: Appropriate service and repair manuals (English version) will be provided with each vendor furnished vehicle and shipped separately to SA7. These manuals may be in book format or on CD-ROMs.

Weight Restriction: The maximum allowable weight of each type of vehicle to be armored is listed under individual specifications for each group. The contractor shall be required to verify this restriction. Weighing must be performed and documented at a local or state government approved scale. The vendor shall provide to the U.S. Department of State a weight certification for each vehicle. The amount of the fuel in the tank will be noted and subtracted from the final figure.

Seat Height: The original height from all seats to the headliner shall be maintained. This shall not be accomplished by raising the roof of the vehicle in a way that could be detected from casual observation. There shall be no degradation of the seat cushion to accommodate the height requirement. Pad may be removed from the headliner to gain an extra inch.

Exterior Vehicle Modifications:

a. The contractor shall refinish and repaint all exterior areas of the vehicle to meet or exceed OEM paint standards. Buffing compound residue shall be cleaned from cracks and crevices of the vehicle.

b. The contractor shall reinforce door latch/striker area, pillars and doors at hinge attachment points. Reinforcement shall start at the floor level and extend up to the roof armor. The door striker shall be attached to the pillar reinforcement. The material shall conform to military specification MIL-46100B or equivalent and welded in place. Any design variations require CO approval.

c. The armor material, including the transparent armor, shall be integrated in the door so that the hinge is directly coupled to the armor and does not rely on the OEM sheet metal to support the armor weight. If the contractor has a proprietary type door hinge that supports the excess weight of the door, the design of the door hinge shall require the approval of the CO before installation. The CO shall either approve or disapprove it within ten working days of his receipt at the CO’s headquarters in Springfield, Virginia. The OEM hinge pin in each hinge shall be replaced with a hardened pin and bushing to be fabricated by the contractor. The hardened pin shall be 125,000 PSI tensile strength or greater. The bushing hinge arrangement shall support the weight of the door and allow easy opening and closing of the door. Detents at half and full open shall hold the door open, but not be above the resistance of an OEM door when opening and closing the door. Check straps shall be installed on all four doors to prevent over-swing on opening.

d. The contractor shall install “U” channel window frames in all four doors to secure flat edged transparent armor. The “U” channel shall overlap the transparent armor by l and ½ inches (38.1 mm) on the inside and outside edges of the ballistic glass. The “U” channel shall be welded in place and metal finished to maintain OEM appearance. The “U” channel shall be secured to the opaque armor to ensure rigidity. The design shall be approved by the CO within ten working days of his receipt of the design at the CO’s headquarters in Springfield, Virginia.

e. The contractor shall install a stainless steel mesh or expanded metal screen 2 inches into the tail pipe and it shall be welded or bolted in place. The design shall be approved by the CO within 10 working days of his/her receipt at CO’s headquarters in Springfield, Virginia.

f. At the request of the CO the contractor shall design, fabricate and install eight (8) tie-down brackets to the chassis of the vehicle. These tie-downs will be fabricated from ¾ cold rolled steel to accommodate 25,000-pound chains and be positioned to provide unrestricted, unidirectional pull. The contractor shall submit designs to the CO, who shall either approve or disapprove within ten working days of his receipt at the CO’s headquarters in Springfield, Virginia.

g. The Contractor shall remove all plastic type door handles and install billet aluminum style door handles. All cables and rods will be installed in a manner to prevent rubbing, chaffing or binding and shall be upgraded by the contractor if requested by the CO.

Interior Vehicle Modifications: All trim items shall be re-worked and/or re-fabricated to bring the vehicle into OEM appearance. Original equipment trim material that has been broken shall not be reused. The contractor shall fabricate new coverings for exposed armor with vinyl or cloth (or a material to be approved by the CO) to match the interior of the vehicle. The contractor shall perform necessary disassembly to accomplish installation of the armor and related systems and reassemble and trim the vehicle. The contractor shall ensure that all interior trim items are kept boxed and/or covered and marked for reinstallation into each vehicle. The contractor shall ensure that when reinstalling carpet to the floor that the carpet is installed/fitted to the new floor contour and all OEM floor mats will correctly fit in the foot well space.

Test and Condition the Vehicle to New Car Dealer “Prep” Standards: The contractor shall have available individual quality assurance inspection reports (including armor material lot numbers and test information) to ensure compliance to DOS armoring specifications at the time of inspection. The vehicle shall be ready for final inspection at the contractor’s facility when the vehicle is prepared to new car dealer “prep” standards. Final test and inspection at the contractor’s facility shall be completed before shipment to place of delivery specified in Section F. Any discrepancies found during the final inspection and test will be repaired and re-inspected by DoS Quality Assurance Inspectors before the vehicle departs the armoring facility. The vehicle will be inspected by the CO or CO’s representative at the time of delivery of each vehicle.

In the case of a GFE and other than factory-new vehicle, the contractor shall maintain inspection documents demonstrating the condition of the vehicle upon receipt. The inspection documentation shall be reviewed and approved by the Government’s Quality Assurance Inspector. Consideration will be given to all “as received” defects based on the inspection upon final delivery.

Progress Inspection: In addition to the routine weekly progress inspections by the U.S. Department of State’s Quality Assurance Inspectors. The U.S. Department of State (DOS) shall be permitted to conduct periodic, unannounced and unescorted inspections of the contractor’s progress and workmanship on vehicles.

Reuse of removed original equipment and trim materials is permitted only if reinstallation achieves or exceeds original equipment quality. The contractor shall notify the CO in sufficient time (not less than seven working days) to permit the CO or the Quality Assurance Inspector to inspect the completed opaque armor installation on the floor, doors, the roof area and rear seat area, both before heat treat (green) and after heat treat and prior to the contractor starting final trim of the interior. The contractor shall notify the CO not less than fourteen (14) working days prior to the completion of all work on the vehicle in order for the final inspection to be scheduled.

Any removed original equipment (Wheels, tires, OEM glass) not reused by the contractor will either be destroyed or disposed. In such cases as original equipment batteries the contractor will recycle these at an approved battery recycler. The contractor should be able to provide documentation of this action when requested by the CO or their representative.

Certifications and Required documentation: The contractor shall provide all heat treat, hardness tests, transparent armor drawings, transparent armor certifications, wiring diagrams, vehicle weight documents, fuel tank certifications, Certificates of Origin, four wheel alignments and any other documentation requested by the CO. These documents will be provided to the Department’s Quality Control inspectors at the time of the final inspection.

Replacement Parts: The contractor shall provide the Government with the following OEM replacement parts. The parts shall be packed, crated, banded and marked with appropriate control number on five sides for overseas shipment with the vehicle:

Special Equipment and Features: The following additional items shall be furnished and installed by the contractor:

Auxiliary Wiring: The contractor shall install and label three (3) 8-Gauge wires (black, red and a blue pull wire) to be run on the left side of the vehicle from the trunk or ‘D’ pillar area and terminating at the electrical center in the engine compartment.

A/C lines, hoses and electrical wire harnesses: The contractor shall secure and protect any A/C lines, hoses or wiring harnesses from chaffing, rubbing and abrading when these areas come in to contact with any armor surface.

Fuel Tank: The contractor shall furnish and install a full process self-sealing Rodgard enhanced OEM capacity fuel tank or equivalent A locking device shall deny access to the fuel filler cap in all model vehicles. Access must be from a locked cover, unlocked with a key or remotely controlled from inside the vehicle.

Fuel Tank Fire Suppression: At the request of the CO the vendor will supply and install a Fire Trace panel around the fuel tank.

Operable Driver Door Window: Unless otherwise directed by the CO, The contractor shall modify the driver door window so that the transparent armor will be operational. It must be capable of opening at least four to six inches (4”to 6”). The contractor can use either electric or a electro-hydraulic system to operate the window but must have a manual bypass to either open or close the window in case of a premature failure of the primary system. The window actuator should be installed using Hex Head Cap screws Extreme-strength steel grade 9 with a minimum tensile strength of 180,000 PSI. Have a class 2a thread fit and a minimum Rockwell hardness of C38. (Also known as L9 screws and are grade-marked with nine radial lines, a dot and the characters L9).

Wheel Inserts: The contractor shall furnish and install Rodgard or equivalent safety roller inserts (constructed of “Hytrel” polyester elastomer) in each tire, including the spare. The contractor shall install a factory valve stem with Tire Pressure Monitor (if originally equipped) and be long enough for normal air check and filling with the wheel cover installed on each wheel. In the event vehicle does not have Tire Pressure Monitor system installed vendor will replace OEM valve stem with a metal valve stem. All wheel-tire-insert units shall be computer spin balanced after assembly. Tire pressure monitors will be recalibrated for the tire pressure set by the CO or their representatives for each vehicle group indicated in the contract.

Upgraded Tires: The contractor shall upgrade the vehicles tires when the OEM tires do not exceed the vehicles GVWR by 10% after armoring.

Interior Mirror: The contractor shall fabricate and install a mirror bracket for the interior rearview mirror. The bracket is to be mounted on the front roof header and positioned for normal viewing through the rear window. The material used to fabricate the bracket will be of a rigid material as to prevent mirror vibration during normal vehicle operations. When requested by the CO the contractor shall fabricate a rearview mirror bracket to accommodate in vehicle camera or GPS mounting on the mirror bracket.

Battery: The contractor shall replace the OEM battery with one that has at least eight hundred (800) cold cranking amps (CCA) (interstate or equivalent). If a battery with eight hundred (800) CCA will not fit, then a battery with the highest available rating will be used. Vendor must have approval from CO before installing a battery with less than 800 CCA.

Vehicle-Emergency Lights: When requested by the CO the contractor shall furnish and install two flashing red and two blue emergency LED lights. These flashing emergency lights will be mounted at the top and behind the grill. The exact location must be approved by the CO. All materials shall be corrosion and rust protected. The control switch for these emergency lights will be controlled from the PA 650 and should be clearly marked.

Fire Extinguisher: The contractor shall furnish and install a hand held fire extinguisher mounted in the rear compartment of the Sport Utility Vehicles, Vans or in the trunk area of the Sedans. The contractor must have written approval from the CO of the type of fire extinguisher to be utilized and the location it will be mounted in the vehicle prior to installation.

Suspension: Prior to any modifications, the contractor shall measure, record, and provide the DOS Quality Inspector and/or the CO, the curb height at all Four Corners of the vehicle. After armoring, these measurements shall be .75” (+/- ¼”) (19.5mm, +/-6.35mm) higher than before armoring. New springs or the adjustment of torsion bars shall be required to maintain this ride height criterion. DOS requires any replacement springs to be from OEM sources. However, if OEM springs are not available, a custom spring manufacturer may be used. The after armoring curb height, as documented, shall be guaranteed for one year after final delivery inspection. The vehicle shall be aligned using four wheel-alignment methods, after all suspension and armoring work is completed. If requested by the CO, the contractor shall replace the OEM sway bar and link bushings with an after market polyurethane set.

Power-train Control Module and Vital Controllers: The power-train control module, vital controllers and under hood components (i.e. fuel rails/lines, mass air flow sensor, crank sensor) shall be armored to the maximum practical extent. This may require complete or partial armoring of the front fenders. The CO must approve the design prior to installation.

Air Bags: The contractor shall install a deactivation switch for all front-seat airbags. This switch will ensure that all front-seat air bags can be quickly deactivated. The control switch for the air bag will be controlled from the PA 650 and should be clearly marked. This switch must be within arm’s reach of the driver and front passenger and be clearly labeled. The contractor will provide clear and concise instruction for the operation of this switch by the vehicle operator.

Child Safety Locks: Where applicable, if a vehicle is equipped with child safety door locks, the locks will be removed or disabled.

Fresh Air Control: The contractor shall provide and install a positive lockout of air through the vehicles air intake system (fresh air intake). The air conditioning system should function with or without use of outside air. The activating switch shall be integrated with the air conditioner control. With the control set at maximum A/C or in the OFF position, all outside air is shut off.

Heavy-Duty Jack: The contractor shall provide a six ton hydraulic bottle jack capable of lifting vehicle after being armored.

Other Contractor Services: The contractor shall provide design and engineering services required for all modifications to the frame, suspension and other related vehicle components.

Security Requirements

(a) A facility security clearance at the Secret level is required for contract performance in accordance with the DD Form 254, Department of Defense Contract Security Classification Specification, attached to this contract.

(b) Since it will be necessary for some Contractor personnel to have access to classified material and/or to enter into areas requiring a security clearance, each Contractor employee requiring such access must have an individual security clearance commensurate with the required level of access prior to contract performance. Individual clearances shall be maintained for the duration of employment under this contract, or until access requirements change.

(c) The Contractor shall obtain a Department of State building pass for all employees performing under this contract who require frequent and continuing access to Department of State facilities in accordance with DOSAR Clause 652.204-70 Department of State Personal Identification Card Policy and Procedures.

(d) Performance of this contract shall be in accordance with the attached DD Form 254, Department of Defense Contract Security Classification Specification and FAR 52.204-2 "SECURITY REQUIREMENTS."

(e) Classified material received or generated in the performance of this contract shall be safeguarded and disposed of in accordance with the National Industrial Security Program Operating Manual (DOD 5220.22-M).