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. ...

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 all, with additional paperwork delays, the Defense Department took 167 days just to start getting the bulletproof vests to soldiers in Iraq once General Cody placed the order. But for thousands of soldiers, it took weeks and even months more, records show, at a time when the Iraqi insurgency was intensifying and American casualties were mounting.

By contrast, when the United States' allies in Iraq also realized they needed more bulletproof vests, they bypassed the Pentagon and ordered directly from a manufacturer in Michigan. They began getting armor in just 12 days.