How to Build a Fiberglass Armour
Making your own fiberglass body armor is probably not as difficult as you might think. Fiberglass is a very easy to work with material that can be set while wet and flexible as you like, then it will dry and harden to an almost rock-like finish, making it an ideal material for custom-made armor. This armor will not be effective protection against anything more than a light tap, so do not use it for purposes other than for costumes. Fiberglass cloth, resin and hardener can all be found at most large hardware or building-supply stores.
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Things You'll Need
- Wax paper
- Fiberglass cloth
- Epoxy resin and hardener
- Paint brush
- Sandpaper (200 and 440 grit)
Instructions
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Dress the person you are making the armor for with whatever he plans to wear under it. This should include any undergarments, shirts, pants or jackets that will be worn in conjunction with the armor.
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Cover the person and his clothing with a layer of wax paper wherever the armor is to be made.
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Mix some epoxy resin and hardener according to the manufacturer's directions, then lay sheets of fiberglass cloth onto the wax paper and saturate and paint on the epoxy using a paint brush. The epoxy will adhere to the wax paper when wet but can be removed easily later.
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Have the person move his limbs and walk around with the fiberglass cloth applied to ensure he will be able to maintain a natural range of motion with the armor on. Add subsequent layers of fiberglass cloth and epoxy until the desired thickness has been achieved.
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Remove the armor sections after allowing the epoxy to slightly harden over the course of an hour, then gently set it aside to allow it to completely cure and harden for 24 hours.
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Sand the surfaces of the armor using a sheet of 200-grit sand paper followed by a sheet of 440-grit paper to smooth the fiberglass to a finished surface. Paint, stain or decorate the armor as desired.
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Tips & Warnings
Do not apply epoxy or fiberglass directly to skin.
Apply epoxy in a well-ventilated area.
References
- Photo Credit Thinkstock/Comstock/Getty Images
