ToyoTa 200H o t - F o r m e d A r m o r e d L A n d C r u i s e r

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

info@jankelts.com www.jankelts.com