Toyota 200

Hot- Formed Armored Land Cruiser

Toyota 200
Hot-Formed Armor
Cutting Edge Technology
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.
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.
Toyota 200
armor system
Benefits to the Customer
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:
qq
qq 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.
qq 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.
qq 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.
qq 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
certification of protection
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.
Ballistic
Certification
VPAM BRV 2009 Level VR7
qq 5.56 x 45 mm (MEN, SS109) FMJ,
PB, SCP [220 rounds fired]
qq 7.62 x 51 mm (MEN, M80) FMJ, FB,
SC [192 rounds fired]
blast
Certification
VPAM ERV 2010
qq 15 kg TNT detonated 2 m from side of
vehicle (note: highest level within the
standard)
qq 2 x DM51 hand grenades detonated
simultaneously on the roof
qq 1 x DM31 hand grenade detonated
under the driver seat
AEP-55
Hybrid-3 Testing
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
qq DM31 anti-personnel mine
detonated under driver’s seat
ERV 2010
qq 15 kg TNT detonated 2 m from
the side of the vehicle
Toyota 200
armor system engineering
Jankel has developed a number
of enhanced protection features
into the vehicle which support
our new Hot-Formed Armor
system.
Material Integration
The 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 Returns
Hot-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
System
The 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 Design
A 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 Profile
All 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
Frames
The 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
systems integration

Each customer has individual
requirements on their vehicles
to meet their specification.
Jankel brings almost a decade of
manufacturing and integration
Systems we have installed into customers’ vehicles include the following:
qq Electronic Countermeasures qq Covert camera systems
Systems (Signal Jammers)
qq Infra-red lighting systems
qq Codan & Barrett HF radios
qq Complete vehicle blackout systems

experience to the customer, qq Motorola VHF radios

qq Customer supplied surveillance
having produced over 1000 qq Satellite phones and eavesdropping equipment
armored Toyota vehicles to date.
qq Vehicle trackers qq Roof hatches

Jankel can fit customer supplied qq Incident data recorders qq Modified seating systems

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.
Toyota 200
complete vehicle engineering
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.
Braking
High performance Alcon
replacement braking system
fitted front and rear, testing
and rated to a GVW of
12,125 lb.
Suspension System
Bilstein 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.
Wheels
Heavy duty Toyota wheels which
are subjected to cornering, radial
fatigue tests and impact tests in
accordance with SAE standards
at 12,800 lb GVW.
Tires
The 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
Certification
The 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
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.
Aspects of the support currently being delivered to customers include:
qq Comprehensive publications qq Management and administration
library that includes Operator of the vehicle warranty.
Handbooks, Illustrated
qq Supply and delivery of Toyota and
qq Spare Parts Catalogs, Jankel spare parts.
RenderSafe Instructions and
qq Technical advice helpline to
Workshop Manuals.
advise on all aspects of fleet
qq Operator / maintainer support.
familiarization training.
qq Ad hoc service visits upon
qq Service & Maintenance plans, request.
covering the first two years of
use, to include four service visits
per year with all parts included.
Toyota 200
production
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 Facilitiy
Our 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 Program
Offering 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
automotive specification

The Hot-Formed armor system was developed for integration into any LC 200 model, the key Upgraded Vehicle
specifications of which are as follows. Dimensions and Weights

Common Land Cruiser 200 Specifications Security Upgrades Dimensions

qq 4.5 L V8 Twin-Turbo-Charged Diesel Engine qq Door deadbolts qq Length 195”
Standard 182 hp @ 3200 rpm; 454 lb-ft @ 1200-3600 rpm
qq 30 mile Hutchinson runflat system qq Width 78”
Intercooled 217 hp) @ 3600 rpm; 430 Nm (454 lb-ft) @ 1200-3600 rpm
qq Siren, PA and Intercom system qq Height 74”
qq 4.0 L V6 VVT-i Gasoline Engine
Dual battery system
240 hp @ 5200 rpm; 277 lb-ft @ 3800 rpm Weights
qq Recovery equipment, tool kit and
qq 4.6 L V8 Gasoline Engine qq GVW 11,020 lb
First Aid kit
314 hp @ 5600 rpm; 339 lb-ft @ 3400 rpm qq Curb 9,040 lb

qq Hi-lo part-time 4WD and rear limited slip differential qq Payload 1,980 lb

qq 20 gallon fuel tank + 10 gallon reserve tank Driving

qq Manual or automatic gearbox qq Fuel Capacity 36 gallons

qq Swing-out barn or lift-up clamshell rear doors qq Range 470 miles

qq Variety of trim and equipment levels available qq Top Speed 90 mph

 J ank e l Tac t ical S y s t e m s , L L C

Washington, D.C. Area Office

7475 Wisconsin Avenue, Suite 820, Bethesda, MD 20814, USA
T 301 547 4084 F 301 547 4088

Duncan, SC Office
190 Parkway West, Suite 100, Duncan, SC 29334, USA
T 864 721 2980 F 864 721 2987

info@jankelts.com www.jankelts.com

A r m o r e d L an d C r uis e r T o y o t a 2 0 0 Ma y 2 0 1 3 v 3 . 0
Jankel believes the content of this brochure to Jankel continuously strives to maintain our

be correct at the time of printing, but makes no technology to cutting edge, market leading

warranty of this. standards and therefore reserves the right to alter

specifications at any time.