What Is Vehicle Armoring and How Is It Done?

Vehicle armoring is the work of rebuilding the cabin of a production car so that it protects its occupants against ballistic threats. The goal is to keep the vehicle's appearance and driving comfort while making the interior safe from bullets and fragments. A well-built armored vehicle is indistinguishable from the standard model from the outside.

Which parts are armored?

Protection is designed as a continuous shell around the cabin. Doors, pillars, roof, floor, rear bulkhead and the firewall between the engine bay and the cabin are lined with ballistic steel or aramid/composite panels. Glass areas are replaced with multi-layer bullet-resistant glass; panels and glass overlap at every joint so no weak point remains.

The process step by step

1. Analysis and design: A panel map is drawn up for the model, the target protection level and the usage scenario.
2. Disassembly: Interior trim, glass and wiring are documented and removed.
3. Panel fabrication and fitting: Panels are CNC-cut and joined to the body with certified welding methods.
4. Glass and mechanical upgrades: Ballistic glass is installed; suspension, brakes and tyres are reinforced for the added weight.
5. Reassembly and testing: The vehicle is returned to its original look and passes road and function tests.

How long does it take and how much weight is added?

A typical SUV takes 8 to 12 weeks. Depending on the protection level, 400 to 900 kg is added, which is why suspension and brake upgrades are an inseparable part of armoring.

At İsso Armor we carry out vehicle armoring projects for Mercedes, Range Rover, BMW, Toyota and many other brands in our own production facility. Contact us to determine the right protection level for your vehicle.