During the Bushranger Phase 1 Project, Tenix Defence (then BAeA) reactivated the engineering data pack and production process sheets from the Land Rover Perentie project on behalf of Land Rover Australia. As these datapacks had not been maintained, Tenix gained experience, unique within Australia, in process engineering for high volume production of military vehicles. Tenix manufactured over 300 vehicles under this contract (4 mockups, 4 prototypes, 265 new vehicles and 53 conversions). No other Australian military vehicle manufacturer has exceeded this number since the original Perentie build. The design content in the Bushranger contract included the design of four new 6x6 variants and one new 4x4 variant for the motorisation role. A large number of design improvements were also included in this program.
Other significant features of the Bushranger Phase 1 program included:
- 4x4 Body Roll and Payload - the in-service RFSV had been acknowledged as a difficult vehicle to handle when laden. Under the Bushranger Phase 1 program a similar new variant, known as the Surveillance and Reconnaissance Vehicle, was required. To improve the vehicle body roll characteristics, Tenix undertook a design program to minimise mass, vehicle moment of inertia in roll, and adapt a Land Rover anti sway kit on the vehicle which improved the handling characteristics within the constraints of the existing design.
- Wheel and Axle Alignment - Tenix redesigned the 6x6 Perentie chassis frame to improve tolerancing on functional dimensions, provided missing functional dimensions and worked through problems with the frame manufacturer to ensure that the new Bushranger 6x6 vehicles had correct wheel alignment.
- Body to Chassis Frame Alignment - Tenix developed extensive experience in body and frame alignment through the design and manufacture of 168 6x6 modules (Infantry Mobility, Assault Pioneer & Mortar variants).
- Roll Over Protection Structure. Tenix designed and manufactured roll over protection structures certified by ATEA for 4x4 and 6x6 vehicles which complied with the Army’s Project Transafe requirements. These ROPS are the only productionised ROPS structures in service and are now fitted to 43 Bushranger 4x4 vehicles and 168 6x6 vehicles.
- Helilift. A rectification program including mechanical testing was developed and conducted by Tenix for the helilift points on the Bushranger 4x4 vehicles.
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