Our skilled and talented workforce assembles all vehicles by hand, from a luxury armored BMW X5 to the cab of a CAT D7 dozer.

  • Technicians are cross trained (30%) in various production processes
  • Our team is experienced in the latest technological advancements in mechanical and electrical diagnostics and regularly perform system validation
  • Our team adheres to the latest ISO standards utilizing calibrated tools and equipment, which creates value by ensuring consistency through rigorous quality control.
  • Automotive Service Excellence (ASE) certified mechanics.


Commercial Armored Vehicle Production: Commercial Armored Vehicle (CAV) production is organized by individual cells for the primary line or steps for specialty build as either a prototype or small volume run in the classified area.  Subcomponent manufacturing occurs in specialized areas and is set up to minimize handling and flow parts to the assembly line on an as needed basis. Once the base vehicle is received, we start with the tear down operation.  Note that prototype build will include the same operations but will be “stall built” meaning the vehicle will be stationary through all operations and specialized staff will move on and off the vehicle during build.  Once the prototype is complete and tested and the customer provides approval to proceed, “cellular production” will occur and vehicles will move through various stations: tear down, modification, armor, mechanical, electrical, trim, final inspection.  The sequential steps described above can occur in many cells or at one station depending on the required talk time (pace of operations) and desired output.

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CAV Process Flow MapAssembly Military Cabs

Military cab assembly is done in a cell-style production line. Cab subcomponents are first assembled off-line and then are brought into the main line to be assembled into the main structure. Once all subcomponents are assembled and inspected to ensure the product meets our quality plan they are “stuffed”. The stuffing operation involves fully building out the interior of the cab – seats, instrument panel, HVAC, insulation, Transparent Armor, and all wiring is installed during this step. A final quality check is performed and the cab is shipped to the supplier on specially designed dunnage. 


Parts for armor kits are nested using a nesting software and nested getting the most efficient use out of the material. Once nested, the nestings are sent to one of three of our lasers in house where Laser Operators cut parts and remove them. Once parts are cut, our laser operators kit the parts into their respective weldments and/or sends them to our bevel parts area or press area for parts to be formed.

Fabrication and Weld

Before parts are welded together, some parts need to be formed or beveled. We form parts using our press and our operators use bevel methods to bevel parts. Once parts are beveled or formed, they are inspected and if passed, our operators will kit the parts with their respective weldments. Once a kit is complete, the kits are sent to the weld area. Once there, a welder will verify the parts and proceed to weld the parts together to create the weldment. Once the weldment is complete, it is inspected and if passed, it is placed on a rack designated for one military cab on the shipping dock to be sent to paint. As an example, one 2-Man D7R cab contains 79 weldments.


Once all weldments are accounted for one Military Cab, it is shipped to be painted. (Or painted in house?) Weldments are shipped as a kit.


Painted parts and weldments are received in and inspected before heading to the assembly line.  Once inspected, good parts and weldments are sent the assembly line. Our team of assemblers assemble the military cabs using prints by engineering and work instructions by manufacturing to build cabs from the ground up. Detailed instructions show our assemblers how to bolt parts together to installing glass. Once the armor cab is built, it is sent to paint for touch up. Once the cab is touched up, our assemblers will place the finishing detail components such as seats, electrical and mechanical components to finish the military cab. Once complete, the military cab goes through a final inspection to ensure we meet the customer requirements and our own requirements which succeeds the customers. Then we ship the cab to the customer.

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O’Gara Armoring is the proud manufacturer of every U.S. President’s limousine from Harry S. Truman to Ronald Reagan.