Tag Archives: defence

Hello, hello, hello.

21 Feb

Last week I, somewhat disingenuously, said that I hoped that Douglas didn’t make any weapons for the MOD because he didn’t like violence. It’s true that he didn’t like violence, and it’s true that I don’t know what he did for the MOD, but I do know that he made several designs over the years for the police that could be classified as weapons, or at the very least, aggressive. Here’s a clue:


Police truncheons, sometimes called batons, were first officially recorded in the 1850s in the UK. Wooden sticks between 6 and 18 inches long, either painted or with a badge affixed, they were the official symbol that someone was a policeman, and as such carried a certain weight of authority over and above their heftiness as a weapon. 150 years later, British police were still using wooden truncheons as part of their uniform. However, the police force at the time was struggling with its image, after clashes and accusations of brutality and racism throughout the 1980s. Thatcherism and the brutal cuts had led to unrest and protest, not always handled well, which built on resentment already simmering, and new laws such as the Police and Criminal Evidence Act of 1984 which extended police stop and search rights, and the Criminal Justice Act of 1988 which laid the groundwork for the later Terrorism Act of 2000 did little to help the matter.  If you’re interested, you can read more about it here, but I will try not to get distracted by interesting social history, and focus instead on what Douglas did about it. In 1993, this little article appeared in the Shropshire Star:


Why would the police need a new truncheon? And why would it improve its community relations with a more ‘caring’ image?

Instinctively, if you pick up a straight truncheon, you are likely to use it to hit things. Try it, it feels like a weapon rather than a form of self defence. And yet self defence is what they are supposed to be used for. Sussex Police, for example, state in their policy that ‘Batons are issued to allow officers to perform their duties and defend themselves or others in accordance with the principles regarding the use of force.’ To defend themselves or others. In addition, wooden truncheons are heavy and awkward to carry, wear and handle, meaning that they could get left behind when getting out of the car or office to deal with a situation; at crucial moments the police officer wouldn’t have it to hand. Maybe after so long, it was time for a new version of the traditional truncheon. Douglas started drawing. I don’t have all of his sketches from that time, but I did find these:




Douglas’s truncheon was made from lightweight metal rather than wood, was telescopic, meaning that it was easier to wear and carry but could still be useful, and the side handle gave greater scope for defence moves and turned it from an aggressive weapon into something more ‘friendly’. The fact that it could be adapted from one shape to the other was unique. Here’s Douglas demonstrating it:



You can read more about the use of batons here (the authors seem to be creepily interested in exactly what kind of wounds can be caused by each type of baton, but there’s also a lot of interesting information too, including the pros and cons of side handles versus straight batons, and why telescoping is a good thing). Looking at that page, and at what the police use now, it’s clear that the batons currently used by the police are not the one that Douglas designed; for example, the handles to side-handled truncheons appear to be screwed into place, whereas it’s clear that Douglas’s handle was not like that. Police having to use them complain about the side handle getting tangled in seatbelts so they have generally fallen out of favour, something that may not have happened if they had used Douglas’s adaptable design. In addition, current police batons seem to be telescoped like an aerial, with a smaller end nested into larger sections, whereas you can see from the photograph that Douglas’s baton had a larger end section. Once again, this shows that Douglas had a really good idea but for some reason or another it didn’t get made, or followed through. I am going to have to find out what happened to this idea. One thing I do know is that Douglas worked with the Met police’s Scientific Department for several years, so I’m going to have to delve into police history to find out how that worked, and why this truncheon didn’t get made and distributed to the police population.

Knife Proof Armour

18 Jan

One of Douglas’s most iconic inventions, for me at least, is his knife proof armour. I asked Mum how Douglas got involved with the police on this, and apparently his second wife’s cousin worked for the Metropolitan Police’s Scientific Department (there’s a whole TV series right there…) and he wondered if Douglas could help. Mum remembers visiting the department (in Isleworth?) and watching the cousin explain the problem. She says he stood next to a bench on which was a piece of flesh simulant (I’d post a picture of this stuff but Googling for it produces nothing but pictures of guns and porn, so, sorry about that, imagine a large block of pinkish plasticine and you’re not far off), on which he had piled four separate armour samples, one on top of the other. She said he casually, almost without looking, took a large knife and stabbed all the way through all four layers into the simulant below. ‘No good,’ he said.

Now, many of you may think that the police have armour already, I mean, what about bullet proof vests? Well, a bullet proof vest is made of layers of a fabric called Kevlar, usually about 30 layers inside a fabric cover. It’s pretty good for stopping bullets, but absolutely hopeless for stopping a knife or needle (at the time people were stabbing the police with dirty needles as well as knives). In fact, the fabric in the vest, which is shiny and slippy, lines the wound, meaning that a knife penetrates further than it would without the vest, actually causing more damage. In addition, Kevlar vests are heavy, bulky and quite rigid from the tightly packed fabric and are therefore uncomfortable to wear, particularly for women.

Douglas took the problem away and had a think about it. Very little remains of Douglas’s sketches for the armour, but I did find this very, very early doodle which I recognise instantly.


You can see him thinking about interlocking tiles, thinking about what shapes fit together and how they might be joined. Here are a couple of other ideas:



What eventually came out of this process wasn’t far from these sketches at all, a series of titanium plates held together with nylon rivets inserted through holes. You’ve already seen a few of them on the dog armour leg protectors. Look closely and you can see the flexible blue rivets, which start as lengths of nylon cut into pieces, then moulded at one end into a mushroom shape, then inserted into the holes of the overlapping plates from the inside to the outside, and then a grey washer is slipped over the end to grip in place and the excess nylon is trimmed to fit. You can see the larger plates on the outside, and then the smaller rectangular plates on the inside that overlap across the joins of the large plates, ensuring full coverage with no cracks or joins where a needle could find its way through.


Here’s Douglas wearing the full vest in a press article:


Titanium is light and strong, it’s what they build planes with, so it’s perfect for vests. The rivets are flexible, meaning the vest bends to suit your shape, making it relatively comfortable to wear. The strength of the metal made it almost bulletproof too (and for years we had some flattened bullets in a little bag in a drawer that had been fired at the vest in tests) and combined with a few layers of Kevlar it was just as bullet proof as the original bullet proof vests, as well as knife and needle proof. Rows of little holes punched into the plates also acted to catch knife tips, meaning that if you were stabbed the knife wouldn’t slip down on impact and accidentally cut you somewhere else. It was, and probably still is, some of the best armour in existence. It got some great press attention, including this:


Exactly what happened with Ross and Catherall and the armour contract is a story for another day, but there was an interesting sideways development that I did not see coming at the time. Douglas was approached by Sainsbury’s for some armour, because it turns out that staff in their butchery department sometimes suffered from slash wounds to their stomach and thighs from accidents dealing with meat carcasses, and Sainsbury’s wanted safety equipment for them. Douglas lengthened the original vest to include a thigh-length skirt, and off they went to protect butchers. Here’s Douglas wearing the long apron version (nothing to do with the salmon story!):

Douglas Buchanan armour Times.jpg