How to Make Body Armor

This is homemade ballistic armor, but not mine.
This is homemade ballistic armor, but not mine.

Do you live in a high crime area? Maybe your an avid outdoors man, who shares his/her space with hunters. Maybe you just like interesting "Arts and Crafts" projects. In this article, I will give you step-by-step instructions about making Ballistics Armor. Armor is completely, 50 state, legal, and, unfortunately, is a good idea for people in certain locations.

Things You'll Need

  • Lots of sheets of cotton.(Buy it new, or cut up old shirts.)
  • Polyester Resin
  • Fiberglass Resin
  • Scissors
  • Something Heavy.(A rock, bowling ball, or iron dumbbell.)

Lay 10, 10"x30" sheets of cotton on a hard surface.(Concrete floor, sturdy table, etc.) Flatten them with something heavy, I prefer using a bowling ball. When they are compressed very tightly, saturate with polyester resin, then put 10 more sheets on top of that, and re-flatten them. Repeat this step until your armor is roughly 50 sheets deep, and about 3.5" thick. Optional: For added protection, you can add alloy(steel, iron, aluminium) plates between every tenth sheet of cotton, however, this will dramatically increase the weight, and thickness of your finnished armor.

Let the stacked, resined sheets dry for 24 hours, in a warm dry location.

Wrap the dried stack in a sheet of material. Seal the wrapping materials with super glue.

Now, you should have a 4" thick stack of resin hardened fabric(Unless you used metal plates, then it could be much thicker.) Apply 1 coat of Fiberglass resin(Font, back,and sides.), every 3 hours for 9 hours, then, let the plate dry for a further 24 hours.

When the plate is completely dry, and has 3 coats of Fiberglass resin, sand the surface down, gently, until it is smooth.

Now, all you need is a plate carrier, which I will teach you how to build in my next article.

Tips & Warnings

  • Look at some professionally made body armor for creative ideas you can use for your own.
  • Take your time!
  • When in doubt, make it thicker.
  • Be conservative with metal plates, the extra weight can become unbearable.
  • This armor is not guaranteed to work, a lot of it has to do with the quality of construction, and, even then, it isn't going to be as effective as the new synthetic fiber, poly armor, but, it's dirt cheap, and dead simple.
  • If your ever assaulted with a deadly weapon, call the police ASAP, because even the best armor can't keep you safe forever.

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