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Many Missteps Tied to Delay in Armor for Troops in Iraq
The war in Iraq was hardly a month old in April 2003 when an Army general in charge of equipping soldiers with protective gear threw the brakes on buying bulletproof vests.

The general, Richard A. Cody, who led a Pentagon group called the Army Strategic Planning Board, had been told by supply chiefs that the combat troops already had all the armor they needed, according to Army officials and records from the board's meetings. Some 50,000 other American soldiers, who were not on the front lines of battle, could do without.

In the following weeks, as Iraqi snipers and suicide bombers stepped up deadly attacks, often directed at those very soldiers behind the front lines, General Cody realized the Army's mistake and did an about-face. On May 15, 2003, he ordered the budget office to buy all the bulletproof vests it could, according to an Army report. He would give one to every soldier, "regardless of duty position."

But the delays were only beginning. The initial misstep, as well as other previously undisclosed problems, show that the Pentagon's difficulties in shielding troops and their vehicles with armor have been far more extensive and intractable than officials have acknowledged, according to government officials, contractors and Defense Department records.

In the case of body armor, the Pentagon gave a contract for thousands of the ceramic plate inserts that make the vests bulletproof to a former Army researcher who had never mass-produced anything. He struggled for a year, then gave up entirely. At the same time, in shipping plates from other companies, the Army's equipment manager effectively reduced the armor's priority to the status of socks, a confidential report by the Army's inspector general shows. Some 10,000 plates were lost along the way, and the rest arrived late. ...