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Mastiff, Afghanistan
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In “Britain Buying New Land Vehicles for Iraqi & Afghan Theaters” (July 26/06), DID noted a trio of vehicle purchases intended to upgrade the survivability of Britain’s army patrols in high-threat areas, as part of a general trend among Western militaries toward high-survivability vehicle designs.

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 and 6×6 “Wolfhound” cargo variants to its fleet.

The UK MoD says that its Mastiff 2 and Ridgback vehicles are now in-theater and operational…

• The Lion’s Cougars [updated]
• The UK’s PPV Program: Contracts & Key Events [updated]
• Additional Readings
• Appendix A: Force Protection, Inc – Expand to Meet Demand (Aug 2006)

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 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.

The UK’s PPV Program: Contracts & Key Events

Wolfhound TSV
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June 10/09: 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: A contract is signed for 97 Wolfhound 6×6 heavy support vehicles, at a cost of about GBP 90 million ($122.6 million equivalent). They will be built by Integrated Survivability Technologies Limited (IST), a 50/50 joint venture between Force Protection Inc., and their partner NP Aerospace in Coventry. The 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: 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 6×6s 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: 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: 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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April 7/09: 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: New Wolfhound variant. 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.

May 1/08: 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 4×4s 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

April 8/08: The Defense Security Cooperation Agency notifies Congress of the United Kingdom’s formal request for another 157 Mine Resistant Ambush Protected (MRAP) Category I 4×4 Cougar vehicles, as well as tools and test equipment, maintenance support, contractor technical and logistics personnel services, support equipment, spare and repair parts, and other related elements of logistics support. This is not a contract, but past British requests have been consistently followed by orders.

The estimated cost is $125 million, and the proposed sale requires the continued support of 7 Field Service Representatives (FSRs), currently providing in theater maintenance support for Britain’s existing Mastiff Cougar 6×6 variants. An additional 8 FSRs will be added under the UK-P-LTR arrangement, and the United Kingdom has requested 1 additional FSR under this proposed sale to support the additional vehicles until July 31/09.

Note that any contract arising from this request will not be part of the Force Dynamics joint venture, which only applies to American MRAP sales. DSCA release [PDF] | Force Protection release.

Feb 21/08: 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: 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: 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: 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 (updated). 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 (Nov 19/09) – Making military vehicles interoperable. Discusses the General Vehicle Architecture project, which aims to create a plug-and-play set of systems.

• 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 (Aug 14/06) – UK Land Forces Order 86 ‘Mastiff PPV’ Cougar Vehicles (updated). We offer details regarding Britain’s purchase of 86 Cougars, aka. Mastiff PPVs, and delve into Force Protection’s efforts to expand production.

• 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 enagaged 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.