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Thread: Aluminum body armour? (stab proof) Reply to Thread
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Topic Review (Newest First)
09-23-2019 06:46 PM
Snyper708 Why do I keep picturing someone covered with flattened beer cans duct taped together?
09-22-2019 09:25 AM
Originally Posted by khanTD View Post
almost forgot, i have kevelar cloth that i was going to use on my limbs, just to keep it light weight, i want to have a full range of motion in a kife fight. nitroboss had a good point about constructing a shield which hadnt occured to me, i shall look into that also
I have a large roll of kevlar aircraft insulation. It would make a stab proof jacket. That stuff is a royal pain to cut.
09-21-2019 11:06 AM
DKdecay I believe the main question here was stab proof. Like a knife etc.

It dosen't take much to stop a knife stab really. In a matter of armour at least.

Proper welded or solded chainmail, at least 1 cm thick wire, will stop a knife stab. Proper padding is advised. Some kind of lamellar armour scales with enough overlap, also does the trick.i would definitely use stainless steel or som kind of medium alloyed carbon steel. Stainless steel is much stronger then mild steel, and can harden when deformed. Such as dishing.

If you have ever seen the pattern of plates in a Jack of plates, your getting there.
05-21-2014 01:25 AM
DWwolf Yes aluminium is soft. It still takes lot of energy to penetrate 2mm of it.
05-18-2014 07:05 PM
birddseedd wouldnt the guy who made bullet proof glass be able to make armor better than soft metal like this?
05-18-2014 06:40 PM
Originally Posted by BumblingBear View Post
Check out Armourarchive. They have many patterns on file there:

Another option is to make plates out of your aluminum to drill holes in and then lace together. This style is called Lamellar.

Honestly, the best thing you can do before attempting any project is to educate yourself about armor.

After that, ask yourself:

- what would fit your body best.

-What attacks are you expecting

-Do you want to have concealable armor or more stout armor

-what crafting tools you have

-what crafting skills you have.

If you're just looking for a plate or two of concealable armor, I would pass on even bothering. In a knife fight or against multiple opponents, a skilled fighter is more likely to bleed you dry than anything else.

However, if you decide to make some real armor, I applaud you. If you take guns out of the mix, a man in full armor and a decent melee weapon is hell on wheels against even a crowd. He's the medieval version of a tank.

People have jokingly said to make a shield, but that is not a bad idea either. A shield and a baseball bat would be awfully hard to get around for most people armed with hand weapons.

Either way, keep us posted on what you decide to do.
I was going to suggest a gambeson covered with 2mm scales.
05-18-2014 06:08 PM
birddseedd wearing armor in public is dumb
05-18-2014 06:07 PM
Axethebarbarian For awhile i did a lot of medieval heavy armored combat with a group called the SCA. Learned a lot about armor and sword fighting. Aluminum armor for the most part will be able to stop a steel knife, but not an axe or spear. Most that used it for armor make a roman type of armor called Lorica segmentata, the overlapping bands allowed it to be more flexible and stronger than a single piece would be. Do not make a helmet out of it! The aluminum is too soft and will fold in half if hit solid with even a simple club, wouldn't want your skull in that. Were it not for the fact that you have a lot of aluminum already I'd say 14 gauge steel would be better in every way, thinner, lighter, and stronger.
05-18-2014 01:08 PM
birddseedd Where do you plan on using this?
05-18-2014 08:48 AM
calidreamer stab proof is a good idea for someone in the UK, where guns are hard to come by. In Cali you don't want to be the one armed with a knife in a gun fight.
for cost you might consider what prisoners do, layers of newspaper under the shirt will turn most prison made blades.
05-14-2014 02:56 PM
Optimist Interesting that a zombie thread like this one comes back up. These have definite temptations, particularly the Roman lorica setmentata and squamata....
05-14-2014 02:45 PM
Hick I always thought one of those heavy duty motorcycle vests with the built in high density padding would make fairly decent stab/slash resistant armor & it could be worn in public with no one being the wiser.
05-14-2014 03:40 AM
DWwolf Brigandine 15th cententury style. 2mm should be enough due to overlapping of plates. Possibly 4mm for the lung plates if your design has em. Heavy linen base. Push rivets through dont punch out the linen base layer. Have fun with the 1600 rivets. Not hard to make just a fair amount of work. Adept a pattern in cardboard folder stock first.
Handgun bullets? About 3 - 4 mm hrc 500 armor plate. Or about 1" of hdpe or umhwpe.
05-13-2014 04:20 PM
Edward4576 want blade about shark proof....
05-13-2014 01:23 PM
TrollFaceTheMan A couple of things...

1.) I am in fact a Black smith and can tell you that aluminium can be used for decent armor, but there is a few things... You can NOT heat forge aluminium like you could steel, or iron or almost any other types of Metals... Aluminum crystallizes at a high temperature and will explode if subjugated to a high impact, like a hammer blow...

2.) Even heating it to extreme temperatures can weaken it, so quenching is not a good way to harden it... But even if that wasn't the case, aluminuium is a Non-Ferrous and will actually get softer with quenching regardless...

However, Cold Hammer Pinging is great for Hardening the metal and shaping it... It works by repeatedly hitting the aluminium with a hammer of some sort, which causes distortion and Twisting in the Metals Crystal Structure, eventually causing them to break into smaller crystals... And that makes it harder. Quenching does the same thing to Ferrous metals, but instead you use heat fracture to break the crystals up.

3.) Aluminum Scale mail would probably be nice for aluminum, because if ever stabbed the scales like to turn in the path of least resistance, typically that results in a glancing blow instead of a direct stab... But in the off chance that somebody hits one directly, they crink inward and that helps to reduce the Impacts force...

I think with a solid, think aluminium plate you'd probably have no issue with someone able to stab through... But if you use Scale mail, always have something else underneath... Even if it is just leather or something... Scale is made for mobility, not protection... Though it can be good for both, it still is not as good as solid Armour...
11-27-2010 04:57 AM
BlindSide i would say if you want to make something stab proof and light you could find some fine wire mesh and use fiberglass resin/fiberglass matting. take the wire mesh and contour it to your torso, then use the mat/resin and if you contoured everything it would be pretty hard for someone to stab through it. think about how solid fiberglass is, and add the wire would take a ton of pressure to stab through it. i plan to make some things out of this 100 ft roll of kevlar we have had in the shop forever. see how it does against a couple pistols.
11-24-2010 07:10 AM
Hubb I honestly think that you will be limiting yourself with the heavier armor if all you are trying to do is keep from getting cut. The weight of the aluminum plates may not seem like much to begin with, but with all of them in place together, they will get a little heavy. And, if you plan on wearing them for extended periods of time, fatigue will become your enemy as well as any attacker. In a knife fight, I would like to think that mobility is better suited as a defensive mechanism. In other words, being able to move out of the way and / or flee is a better option. With heavy armor on top of a fatigued wearer, mobility is going to be crippled and you may not have a choice but to get cut at.

Knife fighters: (I know that there are going to be those "one-uppers" who are going to try and argue the following...) How many professional knife fighters do you know? What I'm trying to say is that, yes there are a few "experts" on the subject that practice chopping at logs and stuff, but how many of those have actually been in a knife fight (and didn't end up cut themselves and / or in jail)? With that in mind, how many people do you know with the precision, under a severely stressful situation, can actually pull off a well placed launch of the blade and land their strike as it was intended, while going toe-to-toe with another using a knife as well? Think about that for a moment, then go back to the above paragraph on mobility.

Chain mail: It has been proven that chain mail is highly effective in stopping a slashing attack. I've even got a pair of chain mail gloves I use when filleting fish (that were purchased for fairly cheap at a bait store). But making a suit of chain mail can be tedious and very time consuming. I've made a suit using PVC rings before (which is a great chest protector when playing paintball or similar...) and, even with a material that is much easier to work with than metal, still took several hours to fashion.

Yesterday, I was repairing a hole in my chicken pen and I used hardware cloth to do this. Thinking back to this thread, I hung a piece up and slashed at it with my machete. It eventually cut through, but it took a few swings to do this. Then I thought, "modern day chain mail". I suppose with a good sized hardware cloth, that this stuff could be fashioned into a slash proof armor fairly quickly and effectively (with the right padding underneath, of course). It would also offer the advantage of a being lighter than regular chain mail, and be much quieter.

Defense of an attack: The primary area I would focus on when trying to make a slash-proof armor, is the arms. This is because when most people come under attack, their primary (sub-conscious) function is to protect the face, which is usually done by throwing up the arms. If the arms are protected from being cut, then a quick defense can be had while still giving you the option to move out of the way / out of the area.

Another excellent form of defense is to have a good offense (now where have I heard that?). If someone brandishes a knife, then you should brandish a bigger one (machete, baseball bat, gun, etc). That, in and of itself would not only give you a reach advantage if the attacker is dumb enough to continue, but may even give the smarter attacker second thoughts to begin with.

I would also like to think that if someone is going to use a knife to hurt you, that they are going to do so when you are not prepared. If they are intent on attacking you, then why would they square off, toe-to-toe, with you? The squaring off is usually reserved when the sneak attack is no longer an option. This means that you would probably have to protect your back, usually from a stab rather than a slice. This means that you should focus on placing your heavier, stab-proof, armor across the back, probably in the upper portion, as a stab will usually come from a downward thrust.
11-22-2010 06:52 PM
Free tip to the boards

I'm big into knives and Eskrima.

One thing i highly suggest is to make cotton lined, vegetable tanned and boiled leather cuirbouilli fore arm protectors.

Use thick silk as the middle layer. even if they get through the cuirbouilli its not likely they are getting through the silk!! YMMV of course(your mileage may vary)

Protect your veins!!! Anytime you get cut= shock.

11-22-2010 05:43 PM
khanTD plates 2,3,4 and four were also tested earlier today, in the prototype these rest on each eaither side of the sternum and the other two below that (then the plan is to over lap them with the 4mm thick, with the 2mm it basicly makes a breastplate except that its more flexible as the 2mm isnt welded or joined to the 4mm underneath but is kept in a different pouch on the jecket. just for anyone that just joined in on the thread, i know this wont be much use against an experianced blade fighter but i am designing for use against the untrained masses, for use when TSHTF. hopefully in conjunction with a riot shield, im talking about that in a different thread.
11-22-2010 02:47 PM
Ashangel Look into MX armor definately. I found some pics of other stuff too, for ideas if nothing else. this how the G20 roll.

And some other stuff.

Also on a side note Samurai used to wear quilted silk under their armor, the reason for this was that if the swords penetrated the armor the silk would not tear and would actually wrap around the sword and keep your innards from becoming your outtards once the sword was pulled out.

Just a cursory glance turned up that lot but there doesn't seem to all that much out there. I'll watch your progress with interest. Keep us posted.
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