How Bulletproof Vehicles Are Made: Behind the Scenes with Donut Media
Recently, the team from Donut Media visited our shop to film an episode exploring how bulletproof vehicles are built. The episode takes viewers inside the process of transforming a standard vehicle into an armored vehicle designed to withstand serious threats.
Below is a closer look at some of the key moments filmed during their visit, including the engineering behind armored builds, ballistic glass testing, and several defensive systems demonstrated during filming.
Filming the Armored Vehicle Build Process
During their visit, the Donut Media team documented several important stages of the armored vehicle build process. While many people associate armored vehicles with thick steel panels or heavy glass, the reality is far more complex.
Before armor can be installed, the vehicle must first be carefully disassembled so technicians can access the structure and electrical systems hidden beneath the interior.
As Dominick explained during the filming process:
“Now our employees come in and take out all the interior parts. We get everything out of the way so we can remove the wire harness.”
Removing the interior allows technicians to access the vehicle’s internal structure before armored materials are integrated. Wiring harnesses, mounting points, and structural components must all be carefully managed to ensure the vehicle continues to function properly after armor is installed.
While observing the process, Donut Media host Justin Freeman noted how challenging it can be to adapt to constantly changing vehicle designs:
“You see the wiring harness just laying there? All that wiring has to be redone. Every year manufacturers like to change stuff, so they have to relearn this entire process for every new vehicle that comes in here.”
Because modern vehicles evolve every year, armored vehicle builders must continuously adapt their approach for each platform they work on.
Once the armor integration process is complete, the vehicle is carefully reassembled and finished to match the luxury and functionality of the original platform.
If you’re curious what completed armored vehicles look like, you can explore our gallery of armored vehicles to see examples of finished projects.
Ballistic Glass Testing
One of the most dramatic demonstrations filmed during the visit involved ballistic glass testing.
To show the difference between standard automotive glass and armored ballistic glass, two different vehicle doors were used during the test. The first door, provided by the Donut team, contained standard factory glass. When the round struck the door, the glass shattered immediately and the projectile passed through the panel.
The second door used 42mm thick B6-rated ballistic glass provided by us. Unlike the standard glass, the ballistic laminate absorbed multiple impacts without allowing the rounds to penetrate.
During the demonstration, Donut Media host Justin Freeman reacted to the moment the glass stopped the round:
“That was impressive. I literally jumped. All the shooting hasn’t bothered me until that. Watching that glass stop it was absolutely incredible.”
Ballistic glass achieves this level of protection through a layered construction designed to absorb and disperse the energy of a projectile.
As Dominick explained during the demonstration:
“In between every layer is another layer of film. It’s like glass, film, glass, film — and that’s what stops the load as it tries to break through.”
When a round strikes the surface, the glass fractures outward, creating the spiderweb pattern visible on the strike face. The layered laminate captures and slows the projectile, preventing it from penetrating the protective barrier.
For a deeper dive into what actually makes a vehicle “bulletproof,” check out our article explaining how bulletproof vehicles work and how armor ratings are classified.
Security Features Demonstrated During Filming
In addition to ballistic protection, the Donut Media team also explored several defensive features designed to deter potential threats.
During filming, two of these systems were demonstrated to show how they function in real-world scenarios.
One of the most memorable moments involved the vehicle’s electric shock door handles. These handles act as a deterrent system, delivering a high-voltage shock intended to discourage unauthorized access to the vehicle.
Both Donut hosts Adam and Justin volunteered to test the system during filming. While Justin handled the shock surprisingly well, Adam’s reaction made it clear just how effective the deterrent can be.
The team also demonstrated a pepper spray dispenser system integrated into the vehicle. For safety purposes during filming, water was used instead of actual pepper spray, allowing the team to safely demonstrate how the system deploys.
While these demonstrations created some memorable moments during the episode, they also highlight how modern armored vehicles often incorporate multiple layers of protection. In addition to ballistic armor and reinforced glass, defensive deterrent systems can provide another layer of security for occupants.
Photo Gallery: Behind the Scenes
Watch “How Bulletproof Cars Are Made”
Why Armored Vehicle Engineering Matters
Building an armored vehicle requires careful engineering to balance protection, performance, and reliability. Each component must work together to create a vehicle capable of withstanding serious threats while remaining practical for everyday use.
From ballistic materials to specialized security systems, every element of the vehicle is designed with safety and durability in mind.
We appreciate the Donut Media team visiting our shop and showcasing the engineering behind armored vehicles. Their episode offers viewers a rare behind-the-scenes look at the work involved in building vehicles designed for serious protection.
If you’re interested in learning more about custom armored vehicles, our team at Quality Coachworks designs and builds vehicles tailored to specific protection requirements and client needs.
