• Old Humvee arrives and is stripped. Most are 1980 to 1985 models, worn-out, damaged, sometimes war-torn.
• Frame is blasted, painted, then disassembled. Each part checked for repair/replacement, frame reassembled.
• Engine, transmission, differentials and smaller parts sent to component shop for rebuild. 6.2-liter diesel engine shelved; 6.5-liter installed. (Army asked for more muscle.)
• Body disassembled. Panels and mechanical parts repaired/replaced. Rebuilt, remarried with frame and components.
• Driven 50 miles for initial road test.
• Back to body shop for complete sanding and paint job. (If tan: sign it might be bound for Iraq; three-color green: might be bound for Afghanistan.)
• Decals, canvas, seats, etc., installed.
• Another inspection, another 50-mile road test.
• Shipped to waiting National Guard unit somewhere in U.S.
(A/C and armor installed in-country, if it later ships overseas)
The Limestone facility has done 8,000 in the last 10 years.
Source: Gary Cleaves, general manager, Maine Military Authority
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