For Marines on the Move, a Rack in a Hard Place May Be a Lifesaver

It looks like a simple auto accessory. But for U.S. Marines deployed in Iraq, what’s known as a Gypsy Rack is a potential lifesaver.

Made exclusively by Camarillo-based Southern California Gold Products Inc., the rack is an easily installed system for carrying six five-gallon jugs at the rear of a Humvee, the all-terrain monster vehicle that serves as a mobile mount for everything from machine guns to antitank missile systems.

And with a 300-mile-long supply line from Kuwait to Baghdad -- on a mission that is taking Marines further inland than any battle in their history -- being able to carry extra supplies is a top concern. That’s where the rack comes in.

“It’s ingenious,” said Capt. Andrew Rodgers of the Marine Corps Systems Command in Quantico, Va., who is in charge of procurement for the Corps’ Humvee A2 fleet. “The more gear you can keep with a person, when he’s isolated, the better his chances for survival.”

In Iraq, the Gypsy Racks being used typically carry five canisters, holding some combination of diesel fuel and water, two of the most vital needs for thousands of troops making their way across the desert. Others carry food, including humanitarian rations, or such things as sleeping bags, tents and combat gear.

The racks were born as a simple way to solve a serious problem. During the 1991 Persian Gulf War, in addition to extra ammunition, troops had to store water canisters and other essential supplies in the back of their vehicles, Rodgers said. That was a particular burden for Marines operating weapons.

“Often you had backpacks or water cans stacked on extra missiles, so if you fired the first one, you had to root through your personal gear to get at additional ammunition while someone was shooting at you,” Rodgers said.

“A Marine needs to be able to look downrange while reaching behind him to grab that second round or additional ammo clip and not have to fumble through a water can or [backpack] to do so.”

In September, a Marine Corps officer from Camp Pendleton asked around for a referral and then approached Glenn Harris, Southern California Gold’s owner, with a request: Could he create for the Marines a way to carry water and other gear on the outside of the Humvee? And could he do it quickly, as the Marines prepared for war against Iraq?

Harris took three days to come up with a winning design: a lightweight rack made of steel tubing, with a bracket system that attaches to the Humvee with just six bolts. He made it so that once the brackets are on the vehicle, the rack slips on and off with quick-release pins and can slide down so the tailgate can be opened without removing the rack.

“I’m just an enterprising, go-to kind of person who likes unique challenges,” Harris said.

The racks were tested to hold 400 pounds, the weight of six, five-gallon cans, though they have been holding up to 700 pounds, Harris said.

“Use of the Gypsy Racks is brilliant, and cheap too,” said Brig. Gen. John Kelley, assistant commander of the 1st Marine Division in central Iraq.

Three weeks after winning his biggest single contract -- the Marines paid him close to $1.5 million, Rodgers said -- the 2,500 racks were shipped to Kuwait.

The feedback has been so positive, Rodgers said, that the Marines have ordered 250 more, expected to ship to Kuwait next week.

“I feel like I’m contributing to something important,” Harris said. “It’s a great feeling.”

Harris, 44, began his career as an off-road car racer and expanded that interest into designing after-market car accessories.

In 1978, Harris started Southern California Gold Products, the company he owns along with Gina Harris, his wife of 23 years.

For the most part, the Harrises’ business has been built on developing products for the movie industry and other car aficionados.

Harris would not divulge revenue for Southern California Gold Products but said it is “several million dollars” annually.

He does most of his design work out of his Camarillo home, and has invented other accessories for the Humvee and its civilian counterpart, the Hummer. Humvees are made by AM General Corp. of South Bend, Ind., a division of closely held Renco Group. The similar, wide-body Hummer is produced for General Motors Corp.

But much of Harris’ time is spent on the road. When he’s not competing in desert car races, he drives to sales calls and subcontractors’ facilities across the Southland, since all Southern California Gold products are manufactured locally, using California-made parts.

“This rack is one of the best things to happen to this vehicle,” said Marine Lt. Jason Iversen of Anderson, Calif., with the 1st Marine Division in central Iraq.

“The rack saves a lot of space. We could do the job without it, but not as easily, that’s for sure.”

Perry reported with the 1st Marine Division and Goldman reported from Los Angeles.