Armouring

Depending on the level of protection and location of our customers, armouring a vehicle is between 4 to 5 weeks. We customise vehicles with some of the highest grade materials available on the market, including aramid, armoured glass and high-strength steel to ensure that a vehicle is protected against threats including military grade and high-power small arms fire, in accordance with the British BS 5051, European EN 1063 and NTC 1417 regulations, and the international regulation UL752 and European DIN.

LEVEL 4

Ballistic protection against: Calibre Magnun 44.
Windows Glass: 18,6 mm aprox.
Armoured parts: Doors, body structure, roof frame, panels' retainers, floor, roof, dash and console reinforcement, fuel tank, Teflon tiers rings, tiers, reinforce bumpers and sides.
Added weight: 160 Kg average, depending on vehicle structure.

 

LEVEL 5

Ballistic protection against: AK 47 / G3 / GALIL / FUSIL 5,56.
Windows Glass: 40 mm aprox.
Armoured parts: Entire cap in ballistic steel, floor covered with explosive wave dissipation and anti-fragmentation fibber, doors, body structure, roof frame, panels' retainers, roof, dash and console reinforcement, fuel tank, Teflon tiers rings, tiers, reinforce front and back bumpers, sides, two way 100 W intercom, electric system protection and main battery box.
Added weight: 800 Kg average, depending on vehicle structure.

LEVEL 6

Ballistic protection against: 7.62X51 Full Metal Jacket
Windows Glass: 46 mm aprox.
Armoured parts: Entire cap in ballistic steel, floor covered with explosive wave dissipation and anti-fragmentation fibber, doors, roof frame, panels' retainers, roof, dash and console reinforcement, fuel tank, Teflon tiers rings, tiers, radiator full ballistic protection, bonnet (hood), reinforced front and back bumpers, sides, two way 100 W intercom, electric system protection and main battery box.
Added weight: 1050 KG average, depending on vehicle structure.

LEVEL 7

Ballistic protection against: 7.62X51mm/ AP*, FJ, BP, HC1 (*Armor Piercing).
Windows Glass: 76 mm aprox.
Armoured parts: Entire cap in ballistic steel, floor covered with explosive wave dissipation and anti-fragmentation fibber, doors, roof frame, panels' retainers, roof, dash and console reinforcement, fuel tank, Teflon tiers rings, tiers, radiator full ballistic protection, bonnet (hood), reinforced front and back bumpers, sides, two way 100 W intercom, electric system protection and main battery box.
Added weight: 1400 KG average, depending on vehicle structure.



Armoring is an art at Mezcal: Mezcal's armoring is professionally integrated into the shell and the doors of the vehicles. The result is complete armored structure that continues to reinforce the original body of the vehicle. The pillar carrying the doors are specially reinforced at the hinge mounting points, which are directly attached to the armoring structure, and the doors are reinforced similar way with hinge mounting points also directly attached to the armoring of doors. In this way, the whole added weight of the armoring of the door is supported by the armored structure of the shell thereby guaranteeing the integrity of the assembly and preventing undue stress on the original body structure. Suspension and brake upgrades are included in the standard specifications, as well as the protection of the battery and the fuel tank.

Most of the Mezcal's production is armored to level B6 but offers a range of protections levels from B4 to B7 based on the European CEN standards, and will also provide protection according to other ballistic standards such as NATO, STANAG, US NIJ, Russian GOST or any specific standard required by the customer.

In B6 level armor we use materials, both opaque and transparent that meets or exceeds the requirements of the European CEN 1522/23 and CEN 1063 standards to the level FB6 for opaque areas and BR6 for transparent areas.

All four sides of the passenger compartment and the roof of the vehicle are protected using high quality armor steel and glass defeating 7.62 x 51mm M80 NATO ball ammunition (US NIJ Level III, CEN Level B6) and 5.56 x 45 SS109 ammunition (CEN Level B5 and B6) at 0° incidence (90° to the surface) and 10 m range according to CEN 1063 and CEN 1522.

With a state of Art Manufacturing facility Mezcal Security Vehicles uses only the finest craftsmanship and dedicated resources for each vehicle conversion. Our team consists exclusively of master craftsmen from all areas of vehicle construction. Mezcal Security Vehicles uses only the highest quality of Armor and Ballistic materials available today for the manufacture of Armored SUV’s, using the state of art laser manufacturing equipment, and CAD-CAM engineered systems. Any client whom would like to visit our facility and view our vehicles and assembly process are welcome and it is worth spending the time as the facility and skill sets are unique and set us apart from other Armouring Companies.


STEP BY STEP ARMORING PROCESS


Once a vehicle and deposit has been received, a work order is put into effect describing the materials and levels of protection that have been requested by the owner of the vehicle.

Step1: The Vehicle is dismantled completely, exposing only the frame to allow the work to begin.

                                               Vehicle Stripping

Step2: Measurements of floor, ceiling, doors and firewalls are taken to fabricate the ballistic parts required to cover and protect each area with opaque armor (steel armor plate and or light weight composites) to all doors, side walls, rear area, roof and the fire wall.

Step3: The fuel tank is removed to protect it with ballistic material and cover it with a water-resistant coating.. Suspension and braking systems of the vehicle are assessed and are modified to support the added weight caused by the armor. Other armoring options for the vehicle are also installed at this time

                                               Heavy Duty Suspensions

Step 4: Full Body Armoring - All Pillar Posts, Side Panels, Kick Panels, Firewall, Headers, Rear Wheel Arches are armored with highest standards of ballistic steel protection and forms a complete self-supporting structure so as to avoid excessive stress on the vehicle’s original structure.

Reinforced Pillars & Hinges: Hinge mounting points are reinforced both in the pillars and in the doors in a way that the armouring of the door is supported by the armouring of the pillar. OEM Hinges are replaced with Heavy-duty hinges with in-built door-stop

                   Pillar and Roof Armoring                         Radiator Protection

Doors & Windows: All doors are armored with ballistic steel. All window areas are overlapped with ballistic steel. This ensures that the passenger compartment is protected even when attacked at the weaker areas.

Roof: Entire roof area covered with ballistic steel to ensure full passenger protection even if attacks are vertical (ie. From bridges or overpasses, 90° angle).

Floor: All of the vehicle's floor area is protected with ballistic steel against fragments and spalling in the passenger cabin (anti-mine protection including DM51 grenade / fragmentation).

                           Armored Firewall                         Floor Armouring

Spall Shields (Bullet Catchers): Spall shields are installed into the door and window overlaps to ensure that the passenger compartment retains full protection even when attacked on angle. Without this protection, occupants would be vulnerable in this common type of attack. Radiator protection: protected with 2 pieces of ballistic steel with air holes.

Step 5: The next step is installing the bullet resistant vehicle glass, which can be from 1" to over 3" thick. These are made to fit OEM window channels, giving them a perfect factory finish.

                                               Pillar and Roof Armoring

Door windows: All OEM glasses are removed and replaced with NIJ/CEN/STANAG tested Multi-layered ballistic glass. The combination of floated glass, Polyvinyl Butyral, Polyurethane, and Polycarbonate, also incorporates a layer of anti-spall film (Spallshield), laminated during the production process, which prevents the entry of glass splinters into the cabin. Its thickness range between 39mm to 80mm.

In superior armoring levels (B6 and B7) the bullet resistant glass is manufactured without offset, integrating them into a structure of broadened frames which provide a higher resistance against blast. The design of the wide overlap system in every door and window aperture area is conceived with the purpose of avoiding the detachment and penetration of glass, as well as doors and hatch, into the cabin.

Windshield: OEM Windshield is removed and replaced with NIJ/CEN/STANAG tested Multi-layered ballistic glass. Its thickness range between 39mm to 80mm.

Step 6: The Vehicle is then reassembles by re-installing the doors and checking for fitness and proper closure. The carpet and roof trim are put back into the vehicle. We then have to do some modifications to the door and sidewall trim due to the added thickness of the armor. All interior parts are replaced in the vehicle with minor adjustments while conserving the original luxury and finishing details. A thorough vehicle check is undertaken in our pre-delivery inspection department that is equipped with brake, suspension and engine testing equipment.


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