Blast Hounds: UK Land Forces Order Mine-Resistant Vehicles

Mastiff, Afghanistan
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In 2006 Britain started purchasing a trio of very different vehicles intended to upgrade the survivability of army patrols in high-threat areas, as part of a general trend among Western militaries toward high-survivability vehicle designs. One of those purchase sets involved blast-resistant, v-hulled wheeled vehicles from US-based Force Protection, in conjunction with its British partners.

Specific figures were not given initially – but those figures have emerged over time, along with field experience to back up the initial pros and cons of Britain’s modified Cougar design. Force Protection Inc. ramped up production capacity to produce the “Mastiff Protected Patrol Vehicles” – and now finds itself in the position of having Britain and Iraq as its most important customers. Britain originally chose Force Protection’s Cougar vehicles over BAE’s RG-33 family, and has elected to continue that trend by adding the 4×4 “Ridgeback” patrol vehicles, 6×6 “Wolfhound” cargo variants, and now the modular 4×4 “Foxhound” light patrol vehicle.

The Lion’s Cougars

Cougar interior
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The original British Cougar 6×6 variant was called the Mastiff Protected Patrol Vehicles (Mastiff PPV) by the British Army. Force Protection produces the basic Cougar vehicles, and NP Aerospace in Coventry integrates British equipment and and up-armors delivered Cougars to create the finished Mastiff vehicle.

Photos were eventually released, to the consternation and puzzlement of many observers. Defense-Aerospace sums it up neatly:

“Compared to the original Cougar vehicle, Mastiff has been fitted with large, vertical armor plates which cover the large vision blocks and weapon firing ports. As the basic Cougar is already protected against RPG warheads, it is unclear why these plates were considered necessary by the British, especially as they totally block the crew’s vision and make it impossible to use the firing ports. The crew is thus blind and disarmed, which does not make much sense in an urban combat context.”

Hard to disagree, unless of course the vehicles were not expected to be used for patrols, but are expected to be used as specialty engineering/ EOD (Explosive Ordnance Disposal) vehicles. DID would add that our information does not give the Cougar protection levels that will stop RPGs. On the other hand, up-armoring the ‘Mastiffs’ the way the British have approached it is equally unlikely to do so; either bolt-on slat armor “side-cages” or reactive armor would be required for that. Photos from the front do indicate slat armor on the sides, and the slab-side configuration does make it possible to fit heavier armor that would help stop explosively-formed penetrator (EFP) land mines that have been sent to Iraq via Iran.

A follow-on “Mastiff 2″ variant adds shock-attenuating seats to reduce back injuries; improved armor; improved axles and suspension to cope with the difficult terrain; better thermal imaging for the drivers; and greater crew capacity.

Ridgback trials
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In May 2008, Britain ordered a lighter 4×4 patrol variant, which corresponds to the USA’s MRAP Category I Cougar vehicles. The 4×4 Ridgback has the same general profile and add-ons as the Mastiff, is nearly 2m shorter and 1m slimmer than the Mastiff, making it easier to use them in tight terrain and narrow urban streets.

For British use, Ridgback incorporates an impressive electronics pack including Bowman communications, electronic countermeasures, night vision and thermal imaging. TV screens inside take multi-camera feeds, and some vehicles will be fitted with a remote weapons system that links those sensors to a joystick-operated machine gun. Other attributes include the standard run-flat tires, modified seats that absorb some of a bomb blast’s initial shock, and easy gear selection and driveability (allowing for British layout differences).

In April 2009, Britain signed a contract for a 6×6 “Wolfhound” cargo supply variant of the Mastiff under its GBP 700 million Tactical Support Vehicles competition. Wolfhound adds a standard truck back to a shortened Mastiff frame, creating a highly protected load carrying vehicle for use in the most dangerous areas. Likely missions include moving bulky stores for use in the construction of forward bases; as a Gun Tractor and Gun Limber for the Royal Artillery’s 105 Light Gun; and carrying general stores like ammunition, food or water along especially dangerous roads.

Ocelot/ Foxhound
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In October 2010, the Ocelot (now Foxhound) 4×4 patrol vehicle collaboration between Force Protection and Ricardo was picked as the preferred candidate for Britain’s Light PPV program. In November 2010, contracts began. Ocelot is based on a modular design with a core automotive armored spine or “skateboard,” and a composite special-to-role pod that can be a troop carrier, cab and flatbed, special forces open concept, etc. Its center of gravity is lower than it appears, as all the heavy items are contained within the V-shaped skateboard: the Steyr 3.2 litre straight six diesel powerpack, propshaft, 6-speed ZF gearbox, AxelTech differentials, fuel tank and all the suspension gear except a torsion bar which is mounted alongside the hull. The V-shape design results in the running gear not intruding into the crew area, making movement from front to back easier while improving protection levels. Bulkheads between vehicle crew and dismounts, and between them and the vehicle electronic equipment such as radios and jammers, give added protection.

Force Protection claims that its Ocelot exceeds the required LPPV mine protection level and offers protection similar to the 6×6 Mastiff Cougar variant, while still meeting LPPV targets for mobility, payload, size and gross vehicle weight. Current pods include patrol, fire support, or protected logistics vehicle, and the patrol vehicle pod has seating for 2 crew and 4 dismounts. Access is through large rear doors, 2 top hatches, or an oversize commander’s door. The pods can be swapped out in the field as the need requires. Foxhound/Ocelot can reportedly be airlifted in a C-130 Hercules aircraft, or even a CH-47 Chinook heavy-lift helicopter.

The UK’s PPV/LPPV Programs: Contracts & Key Events

Foxhound, Afghanistan
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Ocelot modularity
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Dec 22/11: 100 Foxhounds. Britain’s MoD announces that they intend to buy another 100 Foxhound (Ocelot) vehicles, as part of a larger GBP 400 million counter-mine package, but that isn’t a contract yet. One it becomes one, Britain’s ordered fleet will rise to 300 vehicles.

April 13/11: The official UK Forces Afghanistan Blog credits an Australian C-17 for getting the Wolfhound into theater, when all RAF aircraft were tied up transferring 3 Commando Brigade in and 16 Air Assault Brigade out of theater. Loading the plane so it remained balanced in flight took some teamwork, but the flight arrived with 2 Wolfhounds , an ARV (armored repair vehicle), and other specialty vehicles.

Nov 29/10: 200 “Foxhounds”. As expected, Britain signs a GBP 180 million (about $300 million) contract with Force Protection Europe and their partner Ricardo plc, buying 200 Ocelot LPPVs. They were not the only companies involved in its design:

“Foxhound incorporates Formula One racing technology and was devised by engineers from the World Rally Championship, McLaren F1 and BMW. Its engine can be removed and replaced in just 30 minutes and it can drive away from an ambush on only three wheels. Crew and passengers also sit inside a protective pod, which can be quickly adapted to transform the patrol vehicle into an ambulance or supply truck. The first vehicles are expected to be available to troops for training in 2011.”

British Minister of State for Strategic Defence Acquisition Reform Lord Drayson, who announced his return to government during one of his pit stops at Le Mans, must surely approve. As this quote implies, the vehicles will be known as Foxhounds in British service. All of the UK’s other blast-resistant vehicles are named after dogs, and getting its Ocelot vehicles out of trees would probably become tiresome after a while. UK MoD | Force Protection | Defense News.

Oct 18/10: Wolfhound deployed. UK MoD announces that the 6×6 Wolfhound heavyweight cargo protected vehicle is now operational in Afghanistan. Wolfhound is fitted with a 7.62mm general purpose machine gun plus electronic equipment, including electronic countermeasures and tactical satellite navigation. A total of 130 vehicles, for a contract value of GBP 160 million, are expected to be delivered to Afghanistan by fall 2011.

June 25/10: 37 Mastiffs. Defense News reports that the UK is ordering 37 more Mastiff 6×6 vehicles from Force Protection Europe:

“The deal has not been officially announced by the Ministry of Defence, but a spokesman confirmed a contract for the vehicle was signed recently.”

June 23/10: 28 Wolfhouhnds. Defense News reports comments by the new coalition government’s Minister for Defence Equipment, Support and Technology, Peter Luff, who says they will be buying another 28 Wolfhound TSV protected heavy cargo vehicles. This brings the UK’s total Wolfhound orders to 125.

It’s one of a pair of contracts to different manufacturers, reported to be worth a total of GBP 65 million (about $96.8 million). The other manufacturer, Supacat, announces its contract at GBP 45 million, leaving GBP 20 million (about $29.8 million) for the Wolfhound purchase. The UK MoD confirms this figure several days later.

June 23/10: Karrus support. Force Protection Europe in the UK announces a support product for its vehicle fleets. Karrus is a comprehensive closed-loop logistics software management suite. It analyses complex logistics data using inputs from field representatives and other sources, in order to provide a fleet-wide maintenance snapshot. It can also be used to make projections, answering questions like what parts are needed, current fleet availability, projected fleet maintenance costs for the next 10 years, etc.

Force Protection Europe Ltd’s Managing Director, David Hind, sees the system as being useful far beyond Force Protection’s UK products, though it has been tested and used with those vehicles, and does fit well with British support trends. Karrus will be promoted on a global basis, including in the United States by Force Protection Europe’s parent company.

May 25/10: Force Protection Europe is one of the firms invited by the UK MoD to tender for Britain’s LPPV (Light Protected Patrol Vehicle) Demonstration, Production and Support Phases. The invite follows a recently awarded contract placed for 2 Ocelot vehicles, presumably for testing purposes. Force Protection release.

April 13/10: SPV 400. Supacat and NP Aerospace formally unveil their modular SPV 400 4×4 vehicle, which will contend for Britain’s LPPV order. Supacat.

March 8/10: LPPV. Defense News reports that Britain’s Light Protected Patrol Vehicle competition to replace the Snatch Land Rover is down to 2 contenders: Force Protection Europe & Ricardo’s Ocelot, or Supacat and NP Aerospace’s SPV 400. Prime Minister Gordon Brown announced that Britain intends to buy 200 LPPVs, about half of the 400 vehicles originally expected.

Feb 23/10: 23 Mastiffs. Force Protection announces an order for 23 British Cougar Mastiff Explosive Ordinance Disposal (EOD) variants, via a Foreign Military Sales (FMS) contract from Marine Corps Systems Command. The undefinitized contract has a value not to exceed $16.1 million.

The work will be performed in Ladson, SC and is expected to be complete before April 2010. Indeed, the first 5 Mastiff contracted vehicles were delivered on Feb 8/10, 20 days after contract award, thanks to long lead funding that was already in place.

Wolfhound TSV
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Dec 30/09: Poor readiness. Figures obtained by Britain’s Liberal Democrat party indicate that only 134 of Britain’s 271 delivered Mastiffs are considered “fit for purpose” due to maintenance and battle damage, and the new Ridgeback 4×4 vehicles being used for the first time by 11 Light Brigade have just a 60% rate at 73 fit for service of 118 delivered. The first Ridgbacks and Mastiff 2s were deployed in Afghanistan in June 2009. UK’s Times | defense aerospace.

Readiness issues

June 10/09: Afghan deployment. According to the UK Ministry of Defence, the first batch of Mastiff 2 and Ridgback 4×4 vehicles have reached Afghanistan. A total of 300 are now operational.

Upgrades to the newest vehicles include explosive attenuating seats to reduce back injuries; improved armor; improved axles and suspension to cope with the difficult terrain; better thermal imaging for the drivers; and greater crew capacity. See also Sept 8/08 and May 1/08 entries. UK MoD.

April 7/09: 97 Wolfhounds. The UK MoD signs a contract for 97 Wolfhound 6×6 heavy support vehicles, at a cost of about GBP 90 million ($122.6 million equivalent). These Cougar variants will be built by Integrated Survivability Technologies Limited (IST), a new 50/50 joint venture between Force Protection Inc., and their partner NP Aerospace in Coventry. The Wolfhound contract is expected to create 50 new jobs within NP Aerospace and its supplier base. In Force Protection’s words:

“The establishment of IST is intended to provide a single point of contact and design authority for future Force Protection business in the United Kingdom, including new projects, fleet upgrades and logistics support. The Wolfhound award represents the first direct sale to an overseas government of a Force Protection product. All previous Force Protection product orders for non-United States governments have been awarded through the United States Foreign Military Sales (FMS) program.”

See: UK MoD | Force Protection.

Nov 19/08: Force Protection’s Wolfhound, a flatbed truck variant of the Cougar 6×6, wins the UK’s Tactical Support Vehicle (Heavy) competition as the preferred bidder. Force Protection proposes to deliver these vehicles in conjunction with their UK integration partner, NP Aerospace; Chairman and CEO Michael Moody adds:

“We completed design work and built two prototypes for Wolfhound, which is based on our highly successful Cougar vehicle, in just 90 days. During this time we also carried out blast tests and mobility trials.”

The Wolfhounds will be used to carry supplies into the most dangerous areas, and will often operate alongside its Mastiff (6×6) and Ridgback (4×4) brethren. The exact number of vehicles and cost remain unfinalized. UK MoD | Force Protection.

Nov 19/08: 24 Mastiffs. Force Protection announces a not-to-exceed $15 million modification under contract M67854-06-C-5162 from Marine Corps Systems Command, to deliver 24 more Cougar Mastiff 6x6s to the British Ministry of Defence. The undefinitized contract includes vehicles and spare parts, and the vehicles are scheduled for delivery in 2009.

On Oct 29/08, the UK MoD mentioned that that they would buy another 30 Cougar family 6×6 and 4×4 vehicles, in order to improve their training fleet. This may well be part of that order. Force Protection release.

Nov 13/08: Buffalo order. Force Protection, Inc. announces 2 orders for its MRAP Category III Buffalo mine-clearance vehicles, worth $34.1 million. One is a modification to contract M67854-06-C-5162 from Marine Corps Systems Command for a Foreign Military Sales order of 14 Buffalo vehicles to be delivered to the United Kingdom Ministry of Defence. The not to exceed $18.6 million contract is also unfinalized with respect to its total amount, and represents the first orders for the Buffalo vehicle from the United Kingdom.

The Buffalos will be part of Britain’s GBP 96 million Talisman program, which will also include a set of armored engineer-excavator tractors and other related equipment. Work, including vehicle deliveries and sustainment, is to be complete by October 2009. UK MoD announcement.

Sept 8/08: Mastiff 2. A GBP 60 million contract to deliver the new Mastiff 2 variant is announced by British Defence Secretary Des Browne, during a visit to Force Protection’s British partner NP Aerospace.

The Mastiff 2 will have improved axles and suspension to help it cope with harsh terrain, better thermal imaging for the drivers, explosive attenuating seats, improved armor, and greater crew capacity. UK MoD.

Ridgback concept
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May 1/08: 151 Ridgback 4×4. Force Protection Industries, Inc. in Ladson, SC receives a not to exceed $91.55 million contract modification from the UK MoD under previously awarded contract (M67854-06-C-5162), in exchange for 151 vehicles and associated spares. Force Protection notes them as Cougar vehicles; the 4x4s are apparently named “Ridgbacks” in British parlance, and will complement the larger Mastiff vehicles.

Work will be performed in Ladson, SC, with the first vehicle deliveries scheduled to begin in July 2008; work is expected to be complete in July 2009. Funds for this action are provided by the United Kingdom Ministry of Defence and do not expire. The Marine Corps Systems Command in Quantico, VA handles the order on the American side. Force Protection release

Feb 21/08: 174 Mastiffs. The UK contracts for 174 Mastiff vehicles in a not to exceed $115.1 million contract modification, under previously awarded firm-fixed-price contract M67854-06-C-5162. This order includes Mastiff 6×6 MRAP vehicles and associated test sets, spares and support services. Work will be performed in Ladson, S.C., and is expected to be complete in July 2009. Orders are placed via US MARSYSCOM. Force Protection release.

‘Mastiff PPV’
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Oct 8/07: 140 Mastiffs. UK Prime Minister Gordon Brown announces that Britain will buy another 140 or so Mastiff vehicles for use in Iraq and Afghanistan. The MoD intends to finalize the deal for this additional set vehicles “in the next few weeks,” and has set aside GBP 100 million for this purpose. MoD release.

April 25/07: According to the European Defence Agency, Britain’s “Specialist and Utility Vehicles (SUV)” Integrated Project Team is seeking tenders for about 180 “Medium Protected Patrol Vehicles” for “a wide range of patrol tasks” under solicitation EDA-1064. The MPPVs will be wheeled vehicles with a gross weight fully loaded of around 14 tonnes (about 36,000 pounds), offering “very high levels of protection against a number of known and emerging threats of a varied nature including Ballistic, Blast, Mine and Fragmentation” and “a degree of cross country mobility” despite being slated mostly for road and rough track use.

Delivery into service is expected in early 2009, at an estimated cost of GBP 20-100 million. Indications of interest must be in by May 11, 2007 at 12:00 GMT. See full DID coverage: “MPPV: More Mastiffs, or UK MRAP Competition?”

March 14/07: 22 Mastiffs. Force Protection announces a contract modification from the British Ministry of Defence for 22 more blast-resistant Cougar Mastiff Protected Patrol Vehicles (Mastiff PPV). The order will bring the total number of vehicles produced for the British government to 108, which matches the announcement of approximately 100 vehicles in July 2006. The approximate contract value for all 108 Mastiffs is $70.1 million, and Force Protection expects to deliver the last of them by the end of June 2007.

Aug 11/06: 86 Mastiffs. Force Protection Industries, Inc. in Ladson, SC had received a $62.9 million firm-fixed-priced contract for 86 Cougar vehicles, associated spares, field service support, and technical manuals as a foreign military sale for the United Kingdom. Work will be performed in Ladson, SC (60%) and Charlotte, MI (40%), and is expected to be completed by May 2007. The Marine Corps Systems Command in Quantico, VA issued the contract (M67854-06-C-5162)

Additional Readings

• DID FOCUS Article – Cougar Armored Trucks to Stalk Mines on the Battlefield. Includes coverage of all contracts for related foreign sales, and goings-on at Force Protection, Inc.

• DID – UK SAS Commander Quits, Citing Inadequate Equipment. It is the latest in a string of high-level offer resignations over this issue.

• UK MoD (Sept 7/10) – Mastiff protects soldiers from roadside explosion in Helmand

• UK MoD (Sept 2/10) – Warrant Officer helps make Mastiff a Helmand hero. That’s Warrant Officer Class 2 Darren Hugill, Urgent Operational Requirements Warrant Officer at the Defence School of Transport’s Advanced Training Wing, aka. “Mr. Mastiff.”

• UK MoD (Feb 2/10) – Ex-footballer turned soldier survives roadside bomb attack in Helmand. “The force of the blast was incredible. The pressure wave actually snapped a couple of the machine guns in half. We had taken a direct hit under the belly of the Mastiff. The wagon was completely undrivable but it had done its job and saved us, it was damaged but we weren’t.”

• UK MoD (Nov 19/09) – Making military vehicles interoperable. Discusses the General Vehicle Architecture project, which aims to create a plug-and-play set of systems.

• Chester Standard/ Leader (June 24/10) – Troops praise ‘a good bit of kit’ that saved their lives. The Mastiff, in this case.

• UK MoD (Nov 9/09) – Mastiff Group deploys to Afghanistan

• UK MoD (Nov 19/08) – Preferred bidders named for new breed of armoured vehicles

• UK MoD (Oct 29/08) – New Armoured Vehicles for Afghanistan

• UK MoD (June 13/08) – Cougar begins its transformation into the Ridgback. That’s Britain’s 4×4 variant.

• Multi-National Forces – Iraq (June 23/07) – Armored vehicle a hit with British troops.

• UK MoD (June 21/07) – Soldiers give Mastiff the thumbs-up. Of course, the UK MoD wouldn’t be saying anything else. The reactions are consistent with general feedback from other sources, however.

• UK Ministry of Defense (March 13/07) – Defence Minister sees new armoured vehicles in Iraq.

• UK Ministry of Defence (Dec 4/06) – Bulldog arrives at the front line

• UK Ministry of Defence (Sept 14/06) – New Protected Patrol Vehicles for Iraq and Afghanistan put through their paces. The UK releases the first pictures of their ‘Mastiffs,’ prompting observers at Defense-Aerospace to question the design’s logic.

• DID (June 8/06) – BAE Delivering a Cougar Variant for Iraq’s $445.4M ILAV Contract. The contract could go as high as 1,050 Cougar vehicles if all options are exercised, and BAE will also be engaged in production work.

Appendix A: Force Protection, Inc – Expand to Meet Demand (Aug 2006)

Buffalo: IED test
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With more orders in the pipeline from American, Iraqi, and now British customers, meeting production demand has become a challenge for a firm that had just 12 employees at the beginning of 2004.

Force Protection, Inc. recently hired its 500th employee, and a July 17, 20006 release noted that they are engaged in efforts to triple their internal manufacturing capacity. A second and third Cougar production line is being put in place following $41 million of equity financing, and production of its Buffalo variant is also slated to double.

An August 10, 2006 release reveals that the firm delivered 11 of the 12 Cougar Joint Explosive Ordnance Disposal Rapid Response Vehicles (JERRV) requested, and both of the Cougar-derived Buffalo Mine Protected Route Clearance (MPCV) vehicles (aka. “The Claw”) to the U.S. government in July 2006. This compares to 19 Cougar and 3 Buffalo vehicles in June 2006, completing its 122 vehicle contract for the US Marine Corps.

Force Protection’s July 17/06 release said they will even make use of other companies’ capacity to fill present and future orders – and readers who recall our coverage of Iraq’s $445.4 million ILAV contract will remember the addition of production at BAE Land Systems (York, PA and Anniston, AL) and fire truck manufacturers Spartan Chassis (Charlotte, Michigan – note also 40% share above). A subsequent partnership with General Dynamics Land Systems would create the Force Dynamics partnership, though that partnership was restricted to Cougar vehicle deliveries for the US MRAP program.

The firm has stated that with the new measures in place, its leadership believes that they can continue to expand production throughout the rest of 2006.

Post-Script: They did, of course, and plans were underway for additional expansions when American MRAP orders dried up. As our Cougar FOCUS article chronicles, Force Protection is now a firm struggling to survive long-term. It’s export orders to the UK, Iraq, and other foreign customers will be critical to the firm’s future. Especially since their Cheetah light mine-resistant vehicle failed to win the USA’s JLTV contest for a Hummer successor, or the M-ATV bridging program.