By David Sharp,Associated Press Writer

LIMESTONE – The buzz of hydraulic wrenches and clatter of tools fill a cavernous room as workers restore worn-out military Humvees at the former Loring Air Force Base. Even during break time, a few mechanics keep on buzzing away.

Those mechanics hustling to meet their self-imposed quotas know the stakes are high: These Humvees may be headed to Iraq and Afghanistan.

The Maine Military Authority has doubled production to meet demand for Humvees that are being sidelined from the wear and tear of combat operations. Many are being beefed up to receive heavy armor to protect against roadside bombs.

The importance of the work is never far from workers’ thoughts. Some of the most recent arrivals from Kuwait show signs of battlefield damage.

“It’s a matter of us doing our jobs so they can do their jobs,” said Edward Rek, one of the mechanics giving old Humvees a second life.

The Maine Military Authority got its start overhauling surplus Humvees for National Guard units. It was awarded Army contracts worth $22 million for 620 Humvees this year because Army depots in Pennsylvania and Texas were at capacity.

In Maine, monthly production has grown to 220 units, and the authority expects to deliver 1,900 Humvees by year’s end, said General Manager Gary Cleaves.

When it was created in 1997, the Maine Military Authority was the only place overhauling castoff Humvees. It started with 14 civilian workers and eight Humvees.

These days, it employs 540 people and is one of the biggest success stories of the redevelopment of Loring Air Force Base, using the former runway maintenance building, the former jet engine maintenance shop and a former supply warehouse.

Across the former base, Humvees are everywhere.

On a recent day, 250 tan-painted Humvees were ready for delivery. Another 800 were awaiting refurbishing, along with all manner of used military vehicles: M-109 Howitzers, mobile kitchens and laundry units, maintenance trucks, and construction equipment.

Humvees are also a common sight on local roads. All Humvees undergo 150 miles of road tests before being declared fit for military service.

While the Maine Military Authority refurbishes anything with wheels or tracks, it has focused most of its efforts on the military’s workhorse Humvee, known in military parlance as the High-Mobility Multipurpose Wheeled Vehicle.

New Humvees from factories in Indiana and Ohio cost about $72,000 to $75,000 apiece. The refurbished ones cost between $25,000 to $40,000 depending on the contract – providing a substantial cost savings to taxpayers, Cleaves said.

When they arrive, they’re in rough shape. Some have smashed glass, torn sheet metal and burn marks from combat operations. A few were pancaked when parachutes failed to deploy in training. The bulk of them were simply worn out.

Those that cannot be repaired are stripped of useable parts and scrapped. But most of them can be revived by the mechanics.

“Give us a frame and some body parts, and we can do the rest,” said John Langley, assistant supply and production director. “We can build anything.”

All Humvees are getting larger 6.5-liter diesel engines to address soldiers’ complaints that they’re underpowered. They’re also getting updated suspensions and 200-amp alternators. And 300 Humvees are being equipped with beefed-up springs to handle armor plates and thick ballistic glass to better protect soldiers.

They come in all different configurations: troop carriers, ambulances, scout vehicles, and missile carriers.

Before they leave, they’ll be mechanically sound. Body damage will be repaired. And they’ll be repainted. Engines are placed on a dyno for up to three hours to check power, and transmissions are tested on a special machine.

“It has to be right,” Langley said. “When someone out there is running through bullets, they have to be reliable.”

The Maine Military Authority, which is self sustaining, was created to oversee the Maine Readiness Sustainment Maintenance Center and is managed by the Maine National Guard. Mechanics receive an average annual pay of $30,000, and benefits, paychecks and pensions are managed by the state of Maine.

Cleaves sees plenty of additional work down the road. Currently 150,000 Humvees are assigned to National Guard and regular military units. Those assigned to units returning from Iraq and Afghanistan will need some work, he said.

Also, work will continue for National Guard units nationwide, which are currently 12,000 units short of their necessary numbers, he said.

But the Maine Military Authority isn’t stopping there. As it looks to diversify, the company is looking at the possibility of refurbishing school buses, snowplows and other equipment used by state and local governments.

On the Net:

Maine Military Authority http://www.maine.gov/mma/

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