ALUMINIUM ARMOUR

hey all.
i am currently working on an aluminium boba helmet but will be starting a set of alu chest armour.i know some folk out there have done armour in alu but i was wondering if any one has done this.(just hoping to find out if it actually works ok)
1=cutting armour out from light guage aluminium
2=dressing/hammer the edges round to give the armour a thicker look
3=pack the inside with somekind of polystyrene of similer
hopefully by packing the inside this will give the armour a more solid feel to it than having to use thick material of some kind and bear the weight.plus it may give and easier route to attaching it to suit etc .

any help on this = many thanks
paul t

hey,
i'm currently doing my armor out of aluminium too. I made the chest armor out of 0.8mm thick alu. well, i haven't hammered the edges round but i formed some parts of the armor and it is very, very solid.
i don't know how thick your alu is but with my material it works great. easy to form and its not that heavy as I thougt.

greets from sunny germany
Lord

Wickedbeard is the master, you should contact him.