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Every Hull Different Challenger 3 Program Faces Nightmare Of Inconsistent Old Frames

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Challenger 3 tank at DSEI 2025 exhibition / Photo credit: DE&S
Challenger 3 tank at DSEI 2025 exhibition / Photo credit: DE&S

Britain wants build Challenger 3 on old Challenger 2 hulls, revealing both old machine wear and production quality problems

New problems have emerged in developing Britain's new Challenger 3 tanks, complicating work again. So, the old hulls that will be used to produce them are too worn and also have various defects, which suggests the idea of producing them from scratch altogether.

Britain's Ministry of Defence claims it is actively cooperating with industry to accelerate vehicle delivery. Work is also underway to ensure necessary materials and reduce possible risks.

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Challenger 3 tank
Challenger 3 tank / Photo credit: UK Ministry of Defense

Recall that Challenger 3 received a completely new turret with a smoothbore 120mm gun, but old Challenger 2s will be used for hulls. The latter have been actively used by the military in recent decades, which led to certain wear and possible poor condition.

This is indeed an obstacle, but it can be overcome through major overhaul, although it will probably require more funds and time. There are plenty of examples of installing a new turret on even older vehicles, one can recall at minimum Leopard 1 with Cockerill 3105 or even the Skyranger 35 air defense systembeing supplied to Ukraine.

Leopard 1A5 with unmanned Cockerill 3105 turret
Leopard 1A5 with unmanned Cockerill 3105 turret / Open source photo

So here its worth looking at the next stated problem significant difference in sizes between hulls due to different production standards during Challenger 2 production times. This will create a need for additional adjustment of new equipment to each vehicle.

Specifically, concerns relate to new TDSS (Turret Drive Servo System) turret drives, which are needed for the new turret. There are some suggestions that it will now be more rational to manufacture new hulls from scratch.

Challenger 3 tank at DSEI 2025 exhibition / Photo credit: DE&S
Challenger 3 tank at DSEI 2025 exhibition / Photo credit: DE&S

However, this would essentially mean producing tanks from scratch, which would require deploying new industrial capacities. That is, more work, even more costs, and additional delivery delays, which could extend for decades altogether. So such a way out is not very rational here, and if already moving in this direction, then take from available analogues on the world market.

The Challenger 3 project itself is constantly questioned due to possible critical mass increase with the same running gear and very long readiness times. And this is in addition to other failed problems, such as with the Ajax IFV suspended from use.

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