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Enormous Trap Repair for Courthouse In Phoenix

Steel wall plates have bullet holes in them because thin sheet metal was used.

Dave Caldwell

Aug 24, 2026

United States Marshall Service at a courthouse in Phoenix was getting some rounds punching through the wall plates in the range.

During one of our previous visits, we conducted an inspection and found some rounds were escaping the trap and into the walls by punching holes in the sheet metal on the sides. We brought this up in our report and the USMS decided to get it fixed so they called us. We came up with a plane to cover the walls and the rear of the trap with ar500 steel to keep everything contained in the trap and then build a knee wall using ballistic rubber block to form the wall.

We had to bring in several sheets of ar500 steel plate to accomplish this task. To start with, we had to make the steel light enough to actually get it on the walls so we cut 4 foot by 4 foot squares and drilled holes in each sheet to anchor to the wall.

Bare sheet metal wall prior to ar500 install with rubber chunk moved out of the way for access.
Bare sheet metal wall prior to ar500 install with rubber chunk moved out of the way for access.
2 pieces of ar500 installed on the bottom course of the wall toward the leading edge of the trap.
2 pieces of ar500 installed on the bottom course of the wall toward the leading edge of the trap.

Then, using the factory edges, we lined up the seams of each plate and squared them to the floor. This trap is kind of a hybrid. It used to be just a steel trap and later, some years ago, the decision was made to add rubber to it. Once we got to the angles portion of the trap we had to cut the steel to match the angle of the plates and still maintain a straight, flush seam on the lower course of the new steel. Ar500 is extremely hard and does not cut or drill easily so this took a very long time and a lot of consumables to accomplish.

Super tech Cade cutting some ar500 steel plate to get installed. This was done inside the trailer using a welding blanket to help maintain the sparks that were emitted.
Super tech Cade cutting some ar500 steel plate to get installed. This was done inside the trailer using a welding blanket to help maintain the sparks that were emitted.

Finally with the bottom course finsihed, it was time to install the top course from front to back. The steel was heavy enough that we needed a hoist to lift it up into place where we could get the hardware started. Then we would remove the hoist and the hardware used to make that happen and finish the install.

Hoist used to lift the steel into place where it could be temporarily hung long enough to move the hoist out of the way and then finished installing.
Hoist used to lift the steel into place where it could be temporarily hung long enough to move the hoist out of the way and then finished installing.

We continued this method until both courses of steel were installed and looking good. The next step was to create the knee wall with the ballistic rubber block. We determined the best placement to hold all the rubber and still remain effective was about 4 feet in from the leading edge of the trap sides. So we dug a trench into the rubber chunk and started placing rubber blocks down subway tile style. Each block weighs an incredible 107 pounds! We moved about 2400 pounds of rubber by hand!

Ballistic rubber blocks were transported from the garage to the range, each weighing about 107 pounds.
Ballistic rubber blocks were transported from the garage to the range, each weighing about 107 pounds.
About half way through installing all the ballistic rubber block in it's new home.
About half way through installing all the ballistic rubber block in it's new home.

We finsihed installing all the block, shoveled the remainder of the rubber chunk back into the trap and got it spread out for full coverage.

New steel and rubber block installed on the indoor range.
New steel and rubber block installed on the indoor range.
View of the new knee wall and steel plates installed for a finished product.
View of the new knee wall and steel plates installed for a finished product.

We wrapped everything up and showed off our work to a very appreciative customer who can shoot into this trap worry free. Please call us if you have similar needs for your range. Happy shooting!

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