to my vest!
i did away with the velcro last night in favor of small bolts and nuts!
i used #6-32 1/2" flat head screws, secured to the inside of the armor with epoxy putty.
for each screw i used a small bit of putty, shaped into a little roll maybe 1/8" diameter and 1/2" long. i rolled that around the screw, placed the screw down on the armor, and then pressed the epoxy into the armor.
once i had all the screws in place, i put a small dot of grey paint on the end of each screw and VERY carefully placed it on the vest. i had outlines already since i weathered the vest AFTER installing the velcro. after removing the velcro, i had armor shaped clean spots to work with
anyway, i placed the armor down and the grey paint left little dots on the armor. i punched holes with a leather hole punch, and then fitted the armor through.
on the inside i used nuts and washers. i put it on over a t shirt and it wasn't uncomfortable. it shouldn't even be noticeable with the heavy flight suit in between me and it.
here's a quick shot of the inside:
the duct tape is the high tech way my light board is installed