Battery & Fuel Protection

The battery and fuel system are among the most vulnerable and critical components in any vehicle. A disabled battery leaves the vehicle stranded, while fuel system damage can lead to fire or loss of power. Comprehensive protection of these systems is essential for true vehicle survivability in threat situations.

Why Battery Protection Matters

Modern vehicles depend entirely on electrical power. Beyond simply starting the engine, the battery powers:

• Electronic fuel injection: No power means no fuel delivery


• Power steering: Loss of assist makes escape maneuvering difficult


• Electronic locks: Security team may be locked out


• Communications: Radios and phones lose power


• Lighting: Headlights essential for nighttime escape

A single well-placed shot to an unprotected battery can completely disable even a heavily armored vehicle.

Battery Protection Solutions

Armored Battery Box

We install custom-fabricated armored enclosures around the battery:

• Material: Ballistic steel matched to vehicle protection level


• Coverage: Complete 360-degree protection including top


• Access: Maintains service access for maintenance


• Ventilation: Proper battery ventilation preserved

Battery Relocation

When standard battery positions are particularly vulnerable, we relocate batteries to protected areas:

• Trunk placement: Behind rear seat protection


• Under-floor mounting: Protected by floor armor


• Engine bay repositioning: Moving to less vulnerable locations

Dual Battery Systems

Critical-use vehicles can be equipped with redundant battery systems:

• Backup battery: Secondary battery in protected location


• Automatic switching: Seamless power transition if primary fails


• Split systems: Critical systems powered separately

Fuel System Protection

Fuel Tank Armoring

The fuel tank is protected against both ballistic penetration and fire:

• Ballistic wrapping: Kevlar or composite material surrounding the tank


• Steel shielding: Armored plates protecting vulnerable exposures


• Fire-resistant coating: Reduces ignition risk from hot fragments

Self-Sealing Fuel Bladder

The ultimate fuel protection uses military-specification self-sealing bladders:

• Technology: Rubber compound that expands to seal punctures


• Effectiveness: Seals holes up to 12.7mm (.50 caliber)


• Reliability: Proven in military applications worldwide


• Installation: Custom-fitted bladder replaces standard tank

Fuel Line Protection

Fuel lines are often overlooked but equally vulnerable:

• Armored routing: Lines routed through protected areas


• Self-sealing lines: Specialized hoses that seal when punctured


• Redundant feeds: Backup fuel routing for critical applications

Fire Suppression Integration

For maximum protection, we can integrate fire suppression systems:

• Engine bay suppression: Automatic systems triggered by heat or flame detection


• Fuel area protection: Suppression systems around fuel tank and lines


• Manual activation: Driver-controlled emergency suppression


• Agent types: Clean agents that don't damage components

Electric Vehicle Considerations

For electric and hybrid vehicles, battery protection takes on additional importance:

• High-voltage battery protection: Armored enclosures for traction batteries


• Thermal management: Protection must maintain proper cooling


• Crash safety: Armoring must not compromise battery safety systems


• Fire suppression: Specialized systems for lithium battery fires

Our engineering team has developed specialized solutions for electric vehicle armoring that address these unique challenges while maintaining vehicle range and performance.