Exploding Knee Armor

  1. #1

    Exploding Knee Armor

    I bet that subject got your attention.

    Have any of you ever had flexibility problems with your fiberglass knee armor?
    The reason I ask is... you know how when you squat, the circumference of
    your lower thigh expands? If you don't know what I mean, wrap a piece of
    tape tightly around your leg (just above the knee) and watch it burst when
    you squat. Don't try it with your knee armor unless it's sintra.

    Anyway, I'm paranoid that my knee armor is going to explode if accidentally
    squat or kneel while wearing it. In careful tests, the sides spread out, and I
    just know they'd snap if I went down all the way. Have any of you had this
    problem? If so, what did you do to accommodate it? Have any of you ever
    had your knee armor explode because of this? Sounds funny, but I'm totally
    serious.

    Joren Fett

  2. #2
    gorman's Avatar
    Member Since
    Jul 2004
    From
    Auckland, New Zealand
    Posts
    404

    Re: Exploding Knee Armor

    Yeap.. I had one of mine pop just before the Ep3 Premiere! Felt like I was punched in the guts...

  3. #3

    Re: Exploding Knee Armor

    http://www.thedentedhelmet.com/showthread.php?t=10241

    post 14 nothing fixes paranoia like cold hard metel

    GG

  4. #4

    Re: Exploding Knee Armor

    Thanks for the link! That's a good idea.
    I'll have to ask Cruzer how he bent that metal into shape!

    JF

  5. #5
    Cruzer's Avatar
    Member Since
    Aug 2004
    From
    Porterville, California
    Posts
    2,754

    Re: Exploding Knee Armor

    Well Joren Fett it was via a very scientific process... I cut the 3/4" aluminum stock from Home Depot into approximately 15" long pieces and then proceeded to bend them into shape over the circular handrails of my wife's treadmill.

    But I did have to use a pair of vice-grips and the sharp edges of my metal workbench to make the fine bends at the ends of the pieces that turned back toward the armors so that my jumpsuit wouldn't snag when I put them on. I then glued the aluminum stock to the insides with plasti-weld two part epoxy found at Walmart (used epoxy for its flexibility). Sanded and smoothed everything with 60 grit sandpaper and rounded off the ends with the dremel.
    Fin

    Hope this helps, Cruzer

  6. #6
    Skalen Fehl's Avatar
    Member Since
    Dec 2003
    From
    Utah
    Posts
    789

    Re: Exploding Knee Armor

    Wow. I have JD's armor too and I just walk up and down the stairs carefully, lol. Nice work though, Cruzer!

  7. #7
    Cruzer's Avatar
    Member Since
    Aug 2004
    From
    Porterville, California
    Posts
    2,754

    Re: Exploding Knee Armor

    Yeah Skalen Fehl, more than likely JD's knee armor were fine without the reinforcement and in one of the pics of the thread I even show how bendable they are without breakage. But since I've been a victim of knee armor breaking right before an appearance and since JD expressed some concern about the other mod I made, I decided to do the reinforcement.

    I got the idea from reinforcing my other knee armor with sintra strips in a similar manner. But this time with the caliber of the knee armors I decide to take it up a notch and use aluminum for more piece of mind when trooping and transporting. Plus, the aluminum is very lightweight adding virtually no additional weight, and they are still slightly adjustable.

    Cruzer

  8. #8

    Re: Exploding Knee Armor

    Thanks Cruzer.

    I happened to be at both Home Depot and Lowe's a few times today (a few
    times more than I'd planned to, that is), and I found the 3/4" metal strips. I was
    undecided between steel and aluminum. I see that you chose aluminum, which is
    certainly much lighter and easier to bend than steel, but I would have thought
    aluminum would flex too much under pressure rather than reinforce the
    fiberglass. Is your 1/8" thick aluminum resistant to flexing when you bend your
    knee? It IS the 1/8" thick stuff, right?

    Joren Fett

  9. #9
    Cruzer's Avatar
    Member Since
    Aug 2004
    From
    Porterville, California
    Posts
    2,754

    Re: Exploding Knee Armor

    Joren Fett, not only will the steel be much more difficult to bend, but it will add weight to your armor that may cause them to sag on your knee when you're wearing them. Go with the 1/8" aluminum. Plus you want to keep in mind that the aluminum does have a little "give" that you want so you can adjust the flare of the knee armor a little once the reinforcement is installed and allow for "give" for when you do have to bend down while wearing them. But of course the final decision is up to you.
    Cruzer
    Last edited by Cruzer; Nov 28, 2005 at 1:04 AM.

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