Suspension & Brakes

Armoring a vehicle adds significant weight—anywhere from 200 kg for basic handgun protection to over 1,000 kg for military-grade armoring. This additional weight fundamentally changes how the vehicle handles, accelerates, and stops. Without proper suspension and brake upgrades, an armored vehicle becomes dangerous to operate.

The Weight Challenge

The additional weight from armoring affects every aspect of vehicle dynamics:

• Handling: The vehicle becomes more prone to body roll and understeer


• Braking: Stopping distances increase dramatically without upgraded brakes


• Acceleration: The engine and transmission work harder


• Tire wear: Increased load accelerates tire degradation


• Ride quality: The vehicle feels harsh and uncontrolled on factory suspension

Our engineering team carefully calculates weight distribution and specifies upgrades that restore—or even improve—factory handling characteristics.

Suspension Upgrades

Spring Systems

Springs must be upgraded to support the additional load while maintaining proper ride height:

• Coil springs: Heavy-duty springs with 30-100% increased spring rates


• Leaf springs: Additional leaves or complete replacement packs for trucks


• Air suspension: Upgraded air springs and compressors for vehicles so equipped


• Self-leveling: Systems that automatically adjust to maintain consistent ride height

Dampers/Shock Absorbers

Shock absorbers control spring movement and are critical for safe handling:

• Heavy-duty shocks: Increased oil volume and stronger valving


• Adjustable dampers: Allow tuning for different loads or driving conditions


• Remote reservoir shocks: Superior heat dissipation for demanding use


• Electronic suspension: Upgraded control units calibrated for armored weight

Structural Reinforcement

Supporting components must also be upgraded:

• Control arms: Reinforced or replaced with heavy-duty units


• Ball joints: Upgraded to handle increased loads


• Bushings: Firmer polyurethane or solid bushings for precision


• Sway bars: Larger diameter bars to reduce body roll

Brake System Upgrades

Rotors

Larger brake rotors provide more stopping power and better heat dissipation:

• Diameter increase: 20-50% larger rotors where space permits


• Vented designs: Two-piece rotors with superior cooling


• Slotted/drilled: Enhanced heat dissipation and wet-weather performance


• Material upgrades: High-carbon or ceramic composite rotors for extreme duty

Calipers

Upgraded calipers apply more clamping force:

• Multi-piston calipers: 4, 6, or 8-piston designs for even pressure distribution


• Larger piston area: More hydraulic force for stronger braking


• Fixed calipers: Superior performance versus floating designs

Brake Pads

High-performance pads maintain stopping power under extreme conditions:

• Ceramic compounds: Consistent performance from cold to hot


• Semi-metallic: Aggressive bite for emergency stops


• Low-dust formulas: Reduced brake dust for wheel cleanliness

Hydraulic System

The entire brake hydraulic system is evaluated:

• Braided steel lines: No expansion under pressure for firm pedal feel


• Larger master cylinder: Increased fluid volume for bigger calipers


• ABS calibration: Electronic systems recalibrated for changed dynamics

Performance Verification

Every upgraded vehicle undergoes extensive testing:

• Brake testing: Repeated stops from highway speeds to verify fade resistance


• Handling evaluation: Figure-8 and slalom tests to verify stability


• Load testing: Full-load testing to verify suspension capacity


• Road testing: Extended driving to identify any issues