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The Process of Armoring a Vehicle

Mark Caldwell

Updated: Sep 13, 2024

BACKGROUND:

As owners of VASG, we are uniquely qualified to understand all perspectives of the armored car process. From assessing the risk, quantifying the need, influencing decision makers, creating armored vehicle policies for Fortune 500 companies, being the purchaser, custodian and also the end user of armored vehicles around the world and now as manufacturers of armored vehicles we have seen and heard it all! We are your partners in protection not just your supplier.

Selection:

While not technically part of the armoring process, the selection of a specific vehicle, for a specific level of armor, for a specific treat level of each specific client is the first part of armoring a vehicle. Selection therefor is a process by itself and the topic of a future Blog.

The Process of Armoring A Vehicle:

Step One - Receiving and in-processing the vehicle:

  • Complete all shipping/receiving/customs and legal paper work for the master vehicle file. Doing it now saves on big problems later.

  • Complete photo spread interior and exterior of the vehicle for the digital vehicle file.

  • Complete inspection and weighing of the vehicle to include a computer scan of all systems of the vehicle with a printed report placed in the master file.

  • Completely document the receiving condition of the vehicle.

Step Two - Stripping and Protection covering of vehicle:

  • Place protective film on all exposed exterior areas that are painted to help protect from scratches, burns or dents during the armoring process.

  • Remove all interior parts, equipment, flooring and headers and seating from vehicle and place them in protective bags that are correctly labeled to make the final reconstruction and trim-out easier.

  • Take special care with disconnecting and storing the wire-harness.

  • Remove doors and OEM glass.

  • Place vehicle on caster wheel system to make it easier to move the vehicle to and from work stations.

Step Three - Stenciling the vehicle for steel cutting:

  • Even if the make, model and year of the vehicle being armored is already in the stencil inventory it is still necessary to remeasure to confirm exact measurements are correct.

  • If using a CNC laser cutter, it is also important to confirm the electronic stencils prior to cutting.

  • Cut the steel to specifications for armoring level. Lower armor levels that use composite material also need to be measured and confirmed before cutting.

  • Label the steel carefully so the welder/fabricators are placing the pieces in the right order.

Step Four - Welding and fabricating:

  • Just like it sounds

  • Welding, grinding, bending and connecting

  • Hardening key points

  • Ballistic Glass Installation

  • Ballistic floor protection

  • Overlap Installation

  • Radiator, Battery and ECM Protection

Step Five - Suspension Upgraded Installation:

  • Upgraded Shocks and Coils Installation

  • Upgraded Brake Rotors and Brake Lines Installation

  • Run Flat Tire Inserts Installation

  • Heavy Load Tires Installation

Step Six - Paint and Body Work:

  • Vehicle enters a quality inspection in order to have the vehicle worked if needed at paint station

Step Seven - Electric System Reassembly:

  • The Harness is reinstalled

  • Electronic additional equipment installation

Step Eight - Reassembly of the Interior of the Vehicle:

  • Rack with all labeled parts are requested to Storage department

  • All panels, headliner and dashboard are tested and marked to trim and made to fit.

  • All interior parts are reinstalled

  • Final inspection and after armoring weighing of the vehicle

  • Computer scan of all systems of the vehicle

Step Nine - Final Quality Inspection:

  • Water Leak test

  • Complete 7th and final QA tests from bumper to bumper

  • Final Scanner Test to confirm all digital and sensor requirements are met

  • Test Drive

Step Ten - Export:

  • Detailing vehicle

  • Load to container and send to Port


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