cyberpyrot
Active Hunter
Well I have decided to combine all works into one thread where people can ask questions and possibly try constructing there own armor. The Metal used is 3/16 Aluminum Plate that's just shy of 1/4 inch think.
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|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| colspan="3" style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 5052-H32 Aluminum
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| rowspan="3" valign="top" style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Minimum Properties
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Ultimate Tensile Strength, psi
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 33,000
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Yield Strength, psi
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 28,000
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Brinell Hardness
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 60
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| rowspan="7" valign="top" style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Chemistry
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Aluminum (Al)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 95.7 - 97.7%
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Chromium (Cr)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.15 - 0.35%
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Copper (Cu)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.1% max
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Iron (Fe)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.4% max
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Magnesium (Mg)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 2.2 - 2.8%
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Manganese (Mn)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.1% max
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Silicon (Si)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.25% max
|-
Here is the link to where I buy my metal the size you want ar .1875 and .09 the thicker I use for everything but backplate gauntlets and knee armor
Order Aluminum 5052 Sheet in Small Quantities at OnlineMetals.com
Tools Needed
Angle Grinder
PORTER-CABLE PC60TAG 6.0-Amp 4-1/2-Inch Angle Grinder - Power Angle Grinders - Amazon.com
Cut-Off Wheels
Amazon.com: DEWALT DW4518 4-1/2-Inch by 1/8-Inch by 7/8-Inch General Purpose Metal Cutting Wheel: Home Improvement
Sanding Wheel
Amazon.com: DEWALT DW8311 4-1/2-Inch by 5/8-Inch-11 36 Grit Zirconia Angle Grinder Flap Disc: Home Improvement
Grinding Wheel
Amazon.com: DEWALT DW4514 ral Purpose Metal Grinding Wheel, 4-1/2 X 1/4-Inch: Home Improvement
Ball Hammer
http://www.amazon.com/TEKTON-30403-...e=UTF8&qid=1459341177&sr=1-29&keywords=hammer
Mallet
http://www.amazon.com/Performance-T...e=UTF8&qid=1459341213&sr=1-30&keywords=hammer
Anvil (Only needed if you plan on doing the cod)
http://www.amazon.com/Grizzly-G8147...&ie=UTF8&qid=1459341283&sr=1-5&keywords=anvil
Letter Stamps (Only needed if you want to mark the armor)
http://www.amazon.com/TEKTON-6610-3...ie=UTF8&qid=1459341283&sr=1-17&keywords=anvil
Electric Sander (this is for polishing the edges and face so paint will stick can be done by hand)
http://www.amazon.com/WEN-6313-Elec...id=1459341453&sr=1-3&keywords=electric+sander
Metal Files (For filing the LED display hole)
http://www.amazon.com/TEKTON-66631-...=1459341553&sr=1-2-spell&keywords=Metak+Files
Drill (For drilling pilot holes for LED display)
http://www.amazon.com/Black-Decker-...ie=UTF8&qid=1459341713&sr=1-99&keywords=drill
Dremel
http://www.amazon.com/WEN-2307-Vari...ie=UTF8&qid=1459341758&sr=1-2&keywords=dremel
*Note None of these tools need to be top of the line if you are planning on making one set of armor.
Full Chest Displayed on Arkady Vest connected with heave duty snaps.
Some of the tools needed to construct the armor several Hammers, Mallets, Sand bags, Anvil, Vise, Grinders, Drills, Various File's, Band Saw, Power Sander, Dies, Stamps Wooden Blocks and other miscellaneous tools.
I will post more pictures of tools when I get home tonight.
The raw Metal ships as a full sheet of aluminum 3/16" thick 24" X 24" in length. I trace the templates out on and cut out. This Aluminum is also very strong it takes several minutes of hammering for just one piece.
Cutting the the plates the two main tools I use to cut the plates is a saws all and a grinder with a cutoff wheel be very careful doing this use safety glasses and gloves ideally you would want to use a vice to hold the metal.
Here is a video of using the sanding wheel to clean up the edges.
Here is the video hammering the plates
I use 3 types of angle grinder wheels to cut and clean the plates. Cutoff wheels is under to cut the plates from the metal grinder wheel to grind down and high points and a sanding wheel to clean off any burs.
Once the armor pieces are free from the large sheet I begin hammering them from the inside to give them shape needed. Once I have the correct shape I use a high speed grinding wheel to sand the face and all the edges.
When hammering the plates use two blocks of wood to prevent the face of the Plates from getting damaged..
Next I use a power sander to remove most of the surface imperfections.
Once all of this is done I like to stamp my Maker Mark into the armor as will as some one else's name to identify who the armor belongs to
Adding the damage is the final touch this takes a whole different set of tools
Here is a link to my master gallery
https://goo.gl/photos/WZn1SmBkgabjvJwH8
Below I will post the Brasing section "Making the Gauntlets"
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| colspan="3" style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 5052-H32 Aluminum
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| rowspan="3" valign="top" style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Minimum Properties
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Ultimate Tensile Strength, psi
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 33,000
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Yield Strength, psi
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 28,000
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Brinell Hardness
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 60
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| rowspan="7" valign="top" style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Chemistry
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Aluminum (Al)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 95.7 - 97.7%
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Chromium (Cr)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.15 - 0.35%
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Copper (Cu)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.1% max
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Iron (Fe)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.4% max
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Magnesium (Mg)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 2.2 - 2.8%
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Manganese (Mn)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.1% max
|- style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: baseline; background: transparent"
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | Silicon (Si)
| style="margin: 0px; padding: 0px; border: 0px; outline: 0px; vertical-align: top; background: transparent" | 0.25% max
|-
Here is the link to where I buy my metal the size you want ar .1875 and .09 the thicker I use for everything but backplate gauntlets and knee armor
Order Aluminum 5052 Sheet in Small Quantities at OnlineMetals.com
Tools Needed
Angle Grinder
PORTER-CABLE PC60TAG 6.0-Amp 4-1/2-Inch Angle Grinder - Power Angle Grinders - Amazon.com
Cut-Off Wheels
Amazon.com: DEWALT DW4518 4-1/2-Inch by 1/8-Inch by 7/8-Inch General Purpose Metal Cutting Wheel: Home Improvement
Sanding Wheel
Amazon.com: DEWALT DW8311 4-1/2-Inch by 5/8-Inch-11 36 Grit Zirconia Angle Grinder Flap Disc: Home Improvement
Grinding Wheel
Amazon.com: DEWALT DW4514 ral Purpose Metal Grinding Wheel, 4-1/2 X 1/4-Inch: Home Improvement
Ball Hammer
http://www.amazon.com/TEKTON-30403-...e=UTF8&qid=1459341177&sr=1-29&keywords=hammer
Mallet
http://www.amazon.com/Performance-T...e=UTF8&qid=1459341213&sr=1-30&keywords=hammer
Anvil (Only needed if you plan on doing the cod)
http://www.amazon.com/Grizzly-G8147...&ie=UTF8&qid=1459341283&sr=1-5&keywords=anvil
Letter Stamps (Only needed if you want to mark the armor)
http://www.amazon.com/TEKTON-6610-3...ie=UTF8&qid=1459341283&sr=1-17&keywords=anvil
Electric Sander (this is for polishing the edges and face so paint will stick can be done by hand)
http://www.amazon.com/WEN-6313-Elec...id=1459341453&sr=1-3&keywords=electric+sander
Metal Files (For filing the LED display hole)
http://www.amazon.com/TEKTON-66631-...=1459341553&sr=1-2-spell&keywords=Metak+Files
Drill (For drilling pilot holes for LED display)
http://www.amazon.com/Black-Decker-...ie=UTF8&qid=1459341713&sr=1-99&keywords=drill
Dremel
http://www.amazon.com/WEN-2307-Vari...ie=UTF8&qid=1459341758&sr=1-2&keywords=dremel
*Note None of these tools need to be top of the line if you are planning on making one set of armor.
Full Chest Displayed on Arkady Vest connected with heave duty snaps.
Some of the tools needed to construct the armor several Hammers, Mallets, Sand bags, Anvil, Vise, Grinders, Drills, Various File's, Band Saw, Power Sander, Dies, Stamps Wooden Blocks and other miscellaneous tools.
I will post more pictures of tools when I get home tonight.
The raw Metal ships as a full sheet of aluminum 3/16" thick 24" X 24" in length. I trace the templates out on and cut out. This Aluminum is also very strong it takes several minutes of hammering for just one piece.
Cutting the the plates the two main tools I use to cut the plates is a saws all and a grinder with a cutoff wheel be very careful doing this use safety glasses and gloves ideally you would want to use a vice to hold the metal.
Here is a video of using the sanding wheel to clean up the edges.
Here is the video hammering the plates
I use 3 types of angle grinder wheels to cut and clean the plates. Cutoff wheels is under to cut the plates from the metal grinder wheel to grind down and high points and a sanding wheel to clean off any burs.
Once the armor pieces are free from the large sheet I begin hammering them from the inside to give them shape needed. Once I have the correct shape I use a high speed grinding wheel to sand the face and all the edges.
When hammering the plates use two blocks of wood to prevent the face of the Plates from getting damaged..
Next I use a power sander to remove most of the surface imperfections.
Once all of this is done I like to stamp my Maker Mark into the armor as will as some one else's name to identify who the armor belongs to
Adding the damage is the final touch this takes a whole different set of tools
Here is a link to my master gallery
https://goo.gl/photos/WZn1SmBkgabjvJwH8
Below I will post the Brasing section "Making the Gauntlets"
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