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  #1  
Old 09-18-2003, 07:15 AM
Frank J Warner Frank J Warner is offline
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Faux body armor

This is a bit off topic, but I hope one of you can help me out.

My partner's 12-year-old boy has to do a school project in history. They're studying the Roman empire, and have to build or make something typical of the period, preferably related to Roman warfare. (For obvious silly reasons, he can't make or bring a knife or sword to school - zero tolerance.)

He's chosen to make a set of Centurion's body armor, including breastplate and helmet, scaled down so he can wear it during his report to the teacher. He has to do at least 75% of the work on the project himself. The rest can be help from others (namely, me).

Now, I won't let him work with sheet metal. He's a clutz, and has no interest in working with tools. Nor to I know enough about the armorer's art to make something reasonably authentic, which would violate the 75% rule.

I'm thinking something a little less challenging, such as some kind of plastic sheet or dense foam that can be cut with a utility knife, formed with the heat from a hair dryer or heat gun, then painted and patinaed to resemble bronze armor.

If anyone knows of a material like that, specifically what I would ask for and where I could find it, I'd be very grateful.

-Frank J Warner


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  #2  
Old 09-18-2003, 07:37 AM
Mail4Tim Mail4Tim is offline
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Sounds like a good application for Kydex. It's relativly easy to cut and form and then you could cover it with foil if you want a metal look. Just a thought.

Tim
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  #3  
Old 09-18-2003, 07:40 AM
Frank J Warner Frank J Warner is offline
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Here's a picture of what we're trying to do:



(I know somebody's going to suggest Kydex, but we'd like to keep this project under $25 )

-FJW


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  #4  
Old 09-18-2003, 07:47 AM
Mail4Tim Mail4Tim is offline
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Frank,

Too late! I already suggested Kydex. After you posted the photo my wife suggested you try poster board. According to her it is available in metalic finishes, or you can always spray paint it.

Tim
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  #5  
Old 09-18-2003, 07:52 AM
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Gary Mulkey Gary Mulkey is offline
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Frank,

Why don't you check with the costumer at your local college or community theatre. They should be able to point you to a material & supply source.

Gary
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  #6  
Old 09-18-2003, 09:05 PM
Terry_Dodson Terry_Dodson is offline
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walmart

you might try wal-mart, in the craft section. take the picture and show the person there, they may be able to help. i saw some thin stiff foam squares in different colors ther that may work, and can be cut with siccors and tied with sting, you could even put eyelettes in it for the stings to go thru.
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  #7  
Old 09-22-2003, 08:33 AM
Frank J Warner Frank J Warner is offline
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Looks like we're going to use aluminum roof flashing. Comes in rolls 12" x 10' for about $8. Thickness is .010" - easy enough to cut with heavy duty scissors and bend to shape, assemble with miniature brass hinges & pop rivets.

Thanks for all the suggestions. Maybe I'll post a pic when it's all done.

-FJW


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  #8  
Old 09-22-2003, 02:47 PM
Fritzers Fritzers is offline
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Hey Frank, just noticed your a neighbor! I know I don't need to say it, but be carefull with that flashing...the worse cut I have ever had came from roof flashing, 10 stiches and I still have the scar.
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  #9  
Old 09-22-2003, 09:21 PM
Frank J Warner Frank J Warner is offline
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Fritzers. Howdy, neighbor!

Thanks for the warning about the roof flashing. I bought the boy a pair of kid-size work gloves and told him about the sharp edges. We're going to protect them with aluminum HVAC tape after the pieces are cut out. He'll be supervised at all points along the way.

Even so, I expect a couple of gashes before he realizes how dangerous it is. The boy has two older brothers, mom is used to blood, so I'm not worried about her, and we have plenty of band-aids!

-FJW


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  #10  
Old 09-23-2003, 06:16 AM
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Bob Warner Bob Warner is offline
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Frank,

Leather makes good hinges. Just pop rivet leather pieces in place of the hinges. It is cheaper than a bunch of hinges.

I have been out of school 23 years and I am STILL sick of getting homework.


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  #11  
Old 09-23-2003, 08:06 AM
Frank J Warner Frank J Warner is offline
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Quote:
Originally posted by Bob Warner
Leather makes good hinges. Just pop rivet leather pieces in place of the hinges. It is cheaper than a bunch of hinges.

I have been out of school 23 years and I am STILL sick of getting homework.
I agree about the leather, but the boy is stubborn and his mom already bought the hinges.

As for the homework, this is the third boy to go through this Roman history class. So far, I've helped build a scale model of the Pont du Gard bridge and a Roman ballista (catapult type weapon). Just learned over the weekend that the oldest boy has to do a project in American history. Guess what? He's chosen a scale model of Pearl Harbor , complete with Japanese Zeros, battleships, tufts of steel wool to represent smoke & flames . . . . Wouldn't have been so bad if he hadn't used all my blue layout fluid to paint the ocean .

Two more kids to go through THAT class. What could be worse? Battle of the Bulge? Normandy? Midway? My house is going to look like a battle museum!

-FJW


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  #12  
Old 09-23-2003, 08:17 AM
Frank J Warner Frank J Warner is offline
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The Internet's a wonderful thing. We actually found exploded drawings of Roman Lorica Segmentata :



-FJW


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Happiness is tight gibs and a flat platen.
http://www.franksknives.com/
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  #13  
Old 09-26-2003, 11:18 AM
Stephen Stephen is offline
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you could try asking here
http://www.armourarchive.org/
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  #14  
Old 10-01-2003, 05:58 PM
Jeff Mack Jeff Mack is offline
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Quite a few plastics are heat bendible. I've helped make a few suits of medieval European armor using plastic. ABS and Kidex aren't too expensive if you buy it in large sheets from a plastic suplier, and I've even seen armor made from a big plastic pickel barrel.

The method we used:

1. Make patterns for all the pieces using cardstock.
2. Transfer it to the plastic and cut.
3. Heat in an oven till pliable. (up the temp slowly)
4. Have your subject wear a couple heavy sweatshirts.
5. Remove the hot plastic from the oven, and press over the sweatshirts to form.
6. Drill holes to lace together.

Hope that helps. Remember to wear gloves. Have fun

Jeff
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