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MTVR Armor Protection Kit (APK)
MTVR Armor System (MAS)

The MTVR Armor System (MAS) was designed for the 7-ton MTVR. The kit provided complete 360-degree protection, as well as overhead and underbody protection for the crew compartment utilizing Mil-A-46100 High Hard Steel and Metal Composite. Options for the kit included a personnel carrier configuration. The MAS came in two versions. These were a standard configuration and a Reducible MAS that was designed to meet the height restrictions when deployment aboard naval ships and when installed allowed the vehicle to be reducible to 98 inches. The armor kit weighted 10,500 pounds for both the cargo and personnel configurations.

On 7 September 2004 the Oshkosh Truck Corp. of Oshkosh, Wisconsin was awarded an estimated $204,000,000 firm-fixed-price delivery order by Marine Corps Systems Command under previously awarded contract for production, delivery and installation of 920 of ECP-58 MTVR Armor Kits to be installed on the Medium Tactical Vehicle Replacement (MTVR) Standard Cargo vehicles. Work for the armor hardware would be performed by Plasan Sasa in Israel (75 percent) and the raw material hardware would come from various steel manufacturers throughout the United States (25 percent). Work was expected to be completed in December 2005. This contract was not competitively procured. Oshkosh Truck Corp. was the sole manufacturer of the MTVR family of vehicles.

The crew cab and/or cargo body perimeter armor were designed for the MTVR. The perimeter armor was required to withstand multiple (up to 3 rounds within one square foot) 7.62x39 M80 ball rounds fired from a one-meter standoff (threshold) with a 7.62 x 39 Armor Piercing (AP) rounds fired from a one hundred-meter offset (objective). The perimeter armor was required to withstand all fragmentation smaller than 1 inch from an Improvised Explosive Devise (IED) detonated at 4 meters with a 1/4 pound of C4 (objective). The mine protection kit would protect the crew and/or cargo space occupants from blast, fragments, and injurious acceleration effects of blast mines up to the equivalent of 12 pounds of composition B (threshold), 16 pounds of composition B (objective). The bottom fragmentation protection was required to be equivalent to 0.5 inches of aluminum armor (threshold), rolled homogeneous armor (objective), in order to protect the crew from grenades, bomblets, and mortar rounds used as mines. Overhead protection for the crew compartment had to stop 90 percent of artillery fragments (US 155mm high energy (HE) round, M107 (Composition B)) fired from any elevation or azimuth and detonated 60 meters from the vehicle, with a 90 percent confidence level.

In a large warehouse outside of Kuwait City civilian contractors from more than 25 countries around the world work in 2, 12-hour shifts, 7 days a week. They were working around the clock in temperatures reaching 120 degrees to ensure US Marines were protected from improvised explosive devices and small-arms fire during convoy operations by installing new panels, dubbed up-armor, to the gunner's turret, undercarriage and sides of their vehicles. Beginning on 16 July 2004, more than 60 MTVR 7-ton trucks and HMMWVs from the 24th Marine Expeditionary Unit had been fitted with the new armor plates. The up-armor project began in February 2004 when Marine commanders wanted 100 percent side protection on their vehicles. Headquarters, Marine Corps sent a request to Logistics Command to come up with a design for the new armor. Within 28 days of the request, the new up-armor had been prototyped, tested, approved and installed on vehicles headed to Iraq from the I Marine Expeditionary Force.

Armor Holdings, Inc. a leading manufacturer and distributor of security products and vehicle armor systems, announced on 5 October 2004 that it had received a contract award from Oshkosh Truck Company for approximately $115 million to support the US Marine Corps Medium Tactical Truck Vehicle Replacement program (MTVR). The Oshkosh Truck Company had contracted with Armor Holdings' Aerospace and Defense Group to provide armor component systems integration, program management, and systems engineering support.

Armor Holdings estimated that 2004 revenue resulting from the MTVR program would be minimal and as a result did not anticipate adjusting 2004 guidance as a result of this award. Armor Holdings noted that the contract was representative of a developing trend within its business toward armoring an ever-broadening range of vehicle platforms. Armor Holdings produced armoring solutions for a total of 7 different vehicle platforms, including light, medium, and heavy tactical trucks.

Armor Holdings in turn subcontracted to its Israeli based partner, Plasan Sasa, for production of 796 MTVR armor kits to be delivered to the USMC, primarily in 2005. On 12 October 2004 Plasan Sasa, leading developers and manufacturers of combat proven ballistic protection products, announced that it has won a new US Department of Defense contract worth over $100 million as a subcontractor for Armor Holdings Inc. The contract called for Plasan to mount its advanced Armor Protection Kit (APK) on 920 Oshkosh Medium Tactical Vehicle Replacement (MTVR), to be fully deployed by the US Marines by 2005. The contract placed Plasan among the small number of companies worldwide that worked with the US Navy in the field of add-on armor for lightweight military vehicles and trucks.

Plasan's solution for both the armor protection itself and the design of the rear troop carrier complied with the highest technological demands stipulated by the US Navy at the time. Engineered from composite materials, Plasan's battle-proven armor solution was tailored to meet the multiple challenges of various contemporary combat scenarios, from traditional battlefields and urban warfare to low intensity conflicts (LIC). The armor was chosen for the high level of all-round protection it provided to both vehicle and crew against Improvised Explosive Devices (IEDs), mines and other threats. In addition, Plasan's highly cost-effective APK allowed easy and swift assembly and disassembly by crews in the field, according to changing mission specifications. Its fully modular nature allowed it to be easily transferred from one vehicle to another.

Plasan's Armor Protection Kit (APK) was chosen over those from competing contractors after extensive rigorous tests by the USMC, in order to ensure the troops had the most effective protection. The new contract followed on from Plasan's earlier successful cooperation with Armor Holdings Inc. to develop add-on armor for the M915 series of trucks. The project proved Plasan's ability to create the most advanced tailor-made solutions specially designed against customer's specific requirements.

Plasan Sasa was a preferred supplier to the Israel Defense Forces (IDF) and an approved supplier to Ministries of Defense around the world. The focus of its core business was the development, manufacture and assembly of Add-On Armor Protection Kits (APK's) for lightweight military tactical track and wheeled vehicles (APCs/Trucks), fixed and rotary wing aircraft, naval platforms and commercial vehicles, as well as personnel protection armor.

Around 10 November 2004, the Maintenance Center received direction from Marine Corps Systems Command, through Logistics Command, to receive, prepare and ship protective armor kits to II Marine Expeditionary Unit, at Marine Corps Base Camp Lejeune, North Carolina, prior to its scheduled deployment. Upon receiving the raw material from the vendor, Maintenance Center personnel from just about every cost work center joined forces to tackle the job.

Armor plates, pre-cut 3/8-inch metal, were to be blasted, painted and bent to fit the specific vehicles they were tasked to prepare the kits for. Kits had to be produced for the Medium Tactical Vehicle Replacement (MTVR), both doors and underbody, and for the 5-ton trucks, doors and underbody. The only thing they had to do other than prepare the kits was manufacture the brackets and hardware that were needed to mount the plates. Those had to be done in-house in just a few days.

The 5-ton truck kits were delivered to Camp Lejeune by 3 December 2004 and the MTVR kits were there by 6 December 2004. More requirements were expected to come in at a later date. There was the possibility of Maintenance Center Barstow being tasked with designing and producing kits for the P-19 Fire truck, as well as producing kits for some of the ambulances, which were being tested at the time in the Nevada desert.

Maintenance Center Albany concentrated more on producing Marine Armor Kits for the High Mobility Multipurpose Wheeled Vehicle (HMMWV), which contained under armor, new style doors, roof armor, rear armor and ballistic windshields. This was the main reason MCB was given the task of producing the MTVR and 5-ton truck kits. MCB contribution helped take some of the pressure off Albany and allow them to fully concentrate on the hummer kits.




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