ToyoTa 200 Hot-Formed Armor
Cutting Edge Technology
Hot-Formed armor allows Jankel to improve greatly upon conventional armoring methods which are more time consuming, expensive and cannot offer the same consistent and certified level of protection from vehicle to vehicle.
We have applied Hot-Formed armoring techniques to the toyota 200 Series Land Cruiser to offer a highly protected, live-fire certified vehicle which can be rapidly manufactured at a highly competitive market price.
this technology is not available from any other manufacturer of armored toyota 200 Series.
the Hot-Forming technology that Jankel has pioneered in the market place fundamentally changes the protection, delivery and price proposition to the customer when compared to conventional armoring methods.
Conventional armoring comprises
hundreds of pieces of small, flat
armor. Hot-Forming replaces these
with a 36-piece steel armor system
which utilizes large pressed panels
that are shaped to fit into the
vehicle.
this technology delivers
measurable protection, weight, cost
and delivery time benefits to the
customer.
Hot-Formed Armor is used in-house
by luxury car manufacturers due to
its high tolerance manufacturing
properties. For this reason Jankel
have now taken these advanced
technologies further for our NGo,
VIP, government and defense
customer base.
Conventional armoring methods date back to over 100 years ago and are still the industry benchmark. the innovative new hot-forming solution from Jankel makes a giant leap forward to offer the customer the following benefits to improve over that of the conventional approach:
q
q Lighter, faster to produce and
lower in cost. Hot-forming
reduces the armor component
count in the vehicle down to 36
parts, resulting in simplified one-
piece structures and a significant
reduction in welding and bolting
of components.
q the highest levels of blast
certification. Use of large
one-piece components from
the firewall to the rear cargo
area offer an incredibly strong
structure to protect against
blasts; this is particularly
important for front wheel and
side-blast threats.
q Higher levels of blast protection
without compromising the
ballistic protection in any way.
Hot-forming uses an armor
material called BseC510.
unlike conventional ballistic
steel, BseC510 has properties
which optimize hardness and
tensile strength allowing it to
defeat higher levels of blast
without cracking, as well as the
traditional ballistic threats.
q Guaranteed repeatability and
consistency in manufacture.
the formed components are
manufactured using oem
tolerances. All panels are identical
with a tolerance of ± 0.5 mm. For
the first time in the industry, the
production vehicle is guaranteed to
be identical to the tested vehicle.
ToyoTa 200 Armor SyStem
Benefits to the Customer
BallisTic CertIFICAtIoN
BlasT CertIFICAtIoN
aEP-55 HybrId-3 teStING
VPaM BRV 2009 level VR7
q 5.56 x 45 mm (men, ss109) FmJ,
PB, SCP [220 rounds fired]
q 7.62 x 51 mm (MEN, M80) FMJ, FB,
SC [192 rounds fired]
VPaM ERV 2010
q 15 kg TNT detonated 2 m from side of
vehicle (note: highest level within the
standard)
q 2 x DM51 hand grenades detonated
simultaneously on the roof
q 1 x DM31 hand grenade detonated
under the driver seat
testing was also undertaken using a Hybrid-3 dummy to record all the forces sustained by the occupant during the following blast events. Please note that 15 kg tNt at 2 meters produces the same blast pressure as 120 kg at 4 meters. Certificates and reports are available upon request.
sTaNaG 4569 level 1
q DM31 anti-personnel mine
detonated under driver’s seat
ERV 2010
q 15 kg TNT detonated 2 m from
the side of the vehicle
there are many material standards used in the industry by both customers and suppliers which relate to the performance of materials in a laboratory.
there is only one standard which
tests the actual vehicle. this is
the benchmark for the industry
which the customer can trust; this
is the German VPAm standard and
is witnessed by and signed off by
Government officials. The Jankel
Toyota 200 is certified to this level.
ToyoTa 200 CertIFICAtIoN oF ProteCtIoN
Jankel has developed a number of enhanced protection features into the vehicle which support our new Hot-Formed Armor system.
Material integrationthe 36 pieces of steel armor are installed into the vehicle and overlap where they meet creating a strong and robust integrated monocoque. this further reduces welding, bolting, welding-support armor and labour required for installation.
overlaps & spall ReturnsHot-Forming enables Jankel to press the overlap and spall return in one piece as part of the main side panel. this spall return profile aligns with the armor in the door perfectly every time due to oem tolerances of the pressed part.
Front screen Retention systemthe front screen is anchored to the internal A-pillar. this prevents it from being sucked out or pushed into the vehicle in very large side blasts.
Door DesignA frame is fabricated inside the toyota door skin to enable it to carry the whole weight of the steel armor and framed glass ensuring longevity.
Glass ProfileAll side door glass is of a block design and does not use a larger outer laminate. this design assists in side blast protection and general levels of glass durability.
Door Glass Engagement Framesthe door glazings are held within purpose built frames which firmly hold the glass in place during a side blast event to prevent the glass being sucked into or blown out of the vehicle.
ToyoTa 200 Armor SyStem eNGINeerING
each customer has individual requirements on their vehicles to meet their specification. Jankel brings almost a decade of manufacturing and integration experience to the customer, having produced over 1000 armored toyota vehicles to date.
Jankel can fit customer supplied
equipment or can supply the
equipment to the customer
specification.
All vehicles are prepared for
communications installation; such
systems can be installed by the
customer once the vehicles have
arrived, should it be desired.
systems we have installed into customers’ vehicles include the following:
q electronic Countermeasures
systems (signal Jammers)
q Codan & Barrett HF radios
q motorola VHF radios
q satellite phones
q Vehicle trackers
q incident data recorders
q Covert camera systems
q infra-red lighting systems
q Complete vehicle blackout systems
q Customer supplied surveillance
and eavesdropping equipment
q roof hatches
q Modified seating systems
ToyoTa 200 SyStemS INteGrAtIoN
Automotive certification has equal importance to armor certification as the completed vehicle will be subjected to a demanding duty cycle in hazardous conditions. the vehicle must perform safely and reliably on a daily basis and not add to the risks of mission failure or dangers to the user.
It is with this in mind that Jankel has gone further than any other manufacturer in eradicating risk to those who use our product. We have achieved this through working with experts in product development and validation throughout the design process.
BrakingHigh performance Alcon replacement braking system fitted front and rear, testing and rated to a GVW of 12,125 lb.
suspension systembilstein suspension system with heavy duty springs and dual reservoir dampers, steering damper and roll bars, tested and rated to a GVW of 12,125 lb.
WheelsHeavy duty toyota wheels which are subjected to cornering, radial fatigue tests and impact tests in accordance with SAe standards at 12,800 lb GVW.
Tiresthe selected tire has a speed rating of 105 mph and weight rating of 3,200 lb to provide a maximum GVW of 12,800 lb.
complete Vehicle Certificationthe vehicle has also gained certification against the requirements of the european Individual Vehicle Approval (IVA) manual for m1 Passenger cars to prove compliance to UK & eU National roadworthiness requirements
ToyoTa 200 ComPLete VeHICLe eNGINeerING
aspects of the support currently being delivered to customers include:
q Comprehensive publications
library that includes operator
Handbooks, illustrated
q spare Parts Catalogs,
rendersafe instructions and
Workshop manuals.
q operator / maintainer
familiarization training.
q service & maintenance plans,
covering the first two years of
use, to include four service visits
per year with all parts included.
q management and administration
of the vehicle warranty.
q supply and delivery of toyota and
Jankel spare parts.
q technical advice helpline to
advise on all aspects of fleet
support.
q Ad hoc service visits upon
request.
ToyoTa 200 tHroUGH LIFe SUPPort
the Jankel through Life Support team have developed a range of comprehensive support packages on the Hot-Formed Armored toyota Land Cruiser 200 Series which go further than any other armorer in the support of customers in the most hostile environments. effective support of armored vehicles will extend service life, reduce maintenance costs, reduce accidents and increase vehicle availability.
our Field Support team is regularly
supporting humanitarian and
diplomatic customers worldwide,
including hostile environments
such as Libya, Haiti, Lebanon,
Afghanistan, Iraq and Somalia.
the Hot-Formed armor technology delivers significant production benefits to Jankel which are subsequently presented to the customer through lower prices and faster production times.
The key production aspects of the project are as follows:
oEM Toleranced Hot-Formed components the hot-formed panels are pressed and profiled with minimal tolerances to ensure they fit first time, every time. This saves significant amounts of labor at armor installation stage which is reduced to 20 hours per vehicle, an 80% reduction over conventional armouring methods.
This significant decrease in labour content is the largest single contributor to the fast
delivery and lower prices we offer to the customer. Vacuum formed trim components and manufactured looms further reduce production time and increase conformity of production.
large Purpose Built Production Facilitiyour large production facility
in South Carolina is purpose built for armored vehicle manufacture enabling us to scale up production to meet the most urgent customer requirements.
stock Build Programoffering the shortest delivery times to customers means maintaining complete armored vehicles in stock. our stock
program ensure we keep vehicles in the production line which can be completed and adopted by the customer allowing for specifications and options to be detailed for particular requirements. Contact a Jankel representative to see what we have available.
ToyoTa 200 ProdUCtIoN
q 4.5 L V8 twin-turbo-Charged diesel engine
standard 182 hp @ 3200 rpm; 454 lb-ft @ 1200-3600 rpm
intercooled 217 hp) @ 3600 rpm; 430 nm (454 lb-ft) @ 1200-3600 rpm
q 4.0 L V6 VVt-i Gasoline engine
240 hp @ 5200 rpm; 277 lb-ft @ 3800 rpm
q 4.6 L V8 Gasoline engine
314 hp @ 5600 rpm; 339 lb-ft @ 3400 rpm
q Hi-lo part-time 4Wd and rear limited slip differential
q 20 gallon fuel tank + 10 gallon reserve tank
q manual or automatic gearbox
q swing-out barn or lift-up clamshell rear doors
q Variety of trim and equipment levels available
ToyoTa 200 AUtomotIVe SPeCIFICAtIoN
Upgraded Vehicle Dimensions and Weights
Dimensions
q Length 195”
q Width 78”
q Height 74”
Weights
q GVW 11,020 lb
q Curb 9,040 lb
q Payload 1,980 lb
Driving
q Fuel Capacity 36 gallons
q range 470 miles
q top speed 90 mph
Common Land Cruiser 200 Specifications security Upgrades
The Hot-Formed armor system was developed for integration into any lc 200 model, the key specifications of which are as follows.
q door deadbolts
q 30 mile Hutchinson runflat system
q siren, PA and intercom system
dual battery system
q recovery equipment, tool kit and
First Aid kit
A r m o r e d L A N d C r U I S e r t o y o tA 2 0 0 m Ay 2 0 1 3 V 3 . 0
Jankel believes the content of this brochure to
be correct at the time of printing, but makes no
warranty of this.
Jankel continuously strives to maintain our
technology to cutting edge, market leading
standards and therefore reserves the right to alter
specifications at any time.
J A N K e L tA C t I C A L S y S t e m S , L L C
Washington, D.C. Area Office7475 Wisconsin Avenue, suite 820, Bethesda, md 20814, usA
t 301 547 4084 F 301 547 4088
Duncan, SC Office190 Parkway West, suite 100, duncan, sC 29334, usA
t 864 721 2980 F 864 721 2987
[email protected] www.jankelts.com