KLASSEN BUNKER: a new armoured Sprinter with VR8 protection and an anti-drone system under development

Project concept

KLASSEN is developing a new armoured Mercedes-Benz Sprinter intended to become the most dependable Sprinter in the company's range. The KLASSEN BUNKER project envisages VR8 protection, an integrated armoured capsule and a bespoke VIP interior. The company is currently presenting the structural foundation of the future vehicle — the armour components that will be concealed beneath the interior trim once the conversion is complete. These components define the central idea of the project: to create a protected space in which every panel, door assembly and connection forms part of the overall safety system.

At the same time, KLASSEN is working in partnership with another company on a unique anti-drone protection solution for this Sprinter. The combination of an armoured structure and new protective technologies is intended to become a defining feature of the vehicle.

Base vehicle

Sprinter technical specifications

based on: Mercedes-Benz Sprinter 519 — Extra Long

Armoured capsule

The foundation of the protection is a capsule integrated into the rear compartment of the Mercedes-Benz Sprinter. It brings together armoured side walls, doors, pillars, a front partition, a roof and a floor. Its design takes into account the geometry of the body, the positioning of openings and the loads imposed by additional protective components. The new project envisages VR8 protection, with the materials and construction of all ballistic protection elements to be coordinated accordingly.

Joints and overlaps between armour panels

Particular attention is paid to the points where protective elements meet. Panel edges, door openings and areas around the glazing require the same careful engineering as the main armoured surfaces. The design uses an overlap system: adjacent elements cover the joint areas, reducing the vulnerability of gaps. This allows the individual components to form a coordinated protective envelope.

Armoured doors

The doors are moving parts of the armoured capsule, so their design must combine protective performance with mechanical reliability. Installing armour increases the weight of the doors and the loads on the supporting assemblies. Precise fit, stable door alignment and coordination between the doors' protective elements and the armour surrounding the openings are particularly important. When closed, the doors become part of the capsule's overall protective envelope.

Reinforced door hinges

The armoured doors use specially developed hinges manufactured on CNC machines. Attaching them directly to the ballistic steel allows loads to be transferred to the protective structure. This solution takes into account the increased door weight and the need to maintain the correct geometry of the assembly through repeated opening and closing. The hinges make an important contribution to the operational reliability of the armoured Sprinter.

Reinforced pillars and door openings

The pillars in the areas where the armoured doors are fitted serve both protective and load-bearing functions. They provide a base for the reinforced hinges and carry the loads from the door structures. Their construction is coordinated with the adjacent armour panels so that the mechanical fixings and transitions between components remain part of an integrated protection system.

Ballistic glazing

The transparent sections of the capsule are made from multilayer ballistic glass. An inner polycarbonate anti-spall layer is intended to reduce the risk of secondary fragments entering the protected space. It is not only the glass itself that matters, but also how it is installed: the edges of the glazing and the adjacent steel elements must form a coordinated protective structure. The glazing specifications for the new Sprinter are determined in accordance with the project's planned protection level.

Roof, floor and front partition protection

The roof and floor complete the capsule structure at the top and bottom of the vehicle. The front armoured partition separates the protected compartment from the driver's cab. These elements are designed together with the side panels and door assemblies, taking into account the mounting points and the necessary service penetrations. The specific protective characteristics of each area are determined by its construction and the testing programme.

Wheels and Run-Flat system

Maintaining mobility is an important part of the protected vehicle concept. A Run-Flat system is planned for the wheels, allowing the vehicle to continue driving after a tyre loses pressure. This gives the driver an opportunity to leave a dangerous area without stopping immediately to change a wheel. The permissible speed and distance depend on the system installed, the vehicle load and driving conditions.

Corrosion protection for armour steel

Before installation, the steel armour components undergo cathodic electrocoat priming. This industrial coating protects the metal against corrosion and contributes to the durability of the structure. The treatment is particularly important for elements that will have limited accessibility once the vehicle has been assembled and the interior trim installed.

Anti-drone protection

A separate area of the project is the development of anti-drone protection. KLASSEN is currently working with a partner company on a unique solution for integration into the armoured Mercedes-Benz Sprinter. Its purpose is to complement the vehicle's protective capabilities in response to modern threats. The system is under development; its operating principle and technical specifications are not being disclosed at this stage.

Protection level and armouring requirements

The new KLASSEN project envisages VR8 protection. Armour steel, ballistic glazing and structural solutions are selected in accordance with the project requirements and coordinated within a unified protection system.

The design of the protected zone takes into account the material properties and the construction of joints, door openings and glazing installation areas. Particular attention is paid to the compatibility of the armour with the body and door structures, as well as the additional loads resulting from the increase in vehicle weight.

Certification and ballistic testing of glass and steel

The project envisages the use of ballistic glass and armour steel with documented protective characteristics. Verification of material conformity includes ballistic testing involving live firing at samples. The certificates and test results are intended to be included in the vehicle's technical documentation.

The documents must confirm the characteristics of the specific components used in the structure — the ballistic glass and armour steel. Certification of these materials and confirmation of the protection level of the completed vehicle are separate procedures: component certificates alone do not establish that the entire vehicle complies with VR8 protection requirements.