ODST: Project Real Armor.... (Pic Heavy)

Have you ever thought our armor was a little bit on the flimsy side? Just does not have the effect you want. And what happens if a cop goes nuts at seeing an armored guy with a gun and does not know what halo is? Well we have the solution we have project armor....

Now keep in mind this is really just a test for fun DO NOT TEST ARMOR BY SHOOTING IT WHEN SOME HAS IT ON!!! As I get on some strange projects from time to time. ALSO DON'T TRY THIS AT HOME UNLESS YOU ARE UNDER THE SUPERVISION OF A TRAINED PROFECINAL!!!

For this test I will be starting out with an ODST chest plate and if all goes will I plan to do a whole suit. The first shot is made with just smooth cast onyx with (MWNT) Multi Walled carbon nano tubes. It was able to deflect a 22LR HV round with little effort but I did not want to destroy the chest plate so I stopped there as going form 22LR HV to 9mm 115 grain 1300fps per second is a little bit of a jump.

Before

After

As you can see it made a small pucker in the center of the chest it’s about a dimes thickness deep.

Now on to stage 2 - Bringing in the big dogs

Next step I ordered in Kevlar, carbon fiber, and laminating epoxy and of course MWNT's.
First I started out with onyx and MWNT's to get the basic shape which was in error later on. Then I put down two layers of carbon fiber with epoxy mixed with MWNT's then 4 layers of Kevlar with MWNT epoxy, then another layer of carbon fiber with MWNT epoxy. At this point it was less then the carbon fiber and Kevlar was less then 5/32" thick. Then I put down a layer of onyx with chopped Kevlar and carbon fiber mix in. There was about 5 ounces of onyx used in the back. Now in hind sight I should have put down a layer of carbon fiber first before the onyx and one after the backing to keep it from cracking out. But this was also a small scale test.

Enjoy the show...

Now that it’s built on to the fun stuff the shooting the test armor.....
All 9mm ammo was full metal jacket. 8 shoot in total where fired at the chest plate 2 22LR HV, and 5 9mm details of the ammo are in the first picture.







Above pic is with damaged front removed exposing the carbonfiber.

Next pic is of a 350lb man standing on the chest plate after being shot 8 times. The back is hollow so it’s supporting his weight.



I did not trim the armor as I was going to shoot the living hell out of it and did not want to waste more time... Humm making armor to shoot it, yet does not want to waste more time trimming it kind of funny if you think about it.

Now the next stage of testing starts I have ordered in Boron Carbide used in US army issued ballistic plates. And a much tougher epoxy resin that’s used for making metal stamp molds. With twice the strength of onyx., so we will see how it goes will keep you up to date.

Holy crap, this is awesome!

As an Army gal, I'm totally interested your project. I highly doubt I'll be able to use your same process but kudos to you for making it real! I'm quite curious to see how much this will all weigh when it's done. Our new IBA's are okay but sometimes they feel like heavy duty, bullet proof corsets! XD They also don't "breath" very well.

For starters, nice work with the build, everything looks extremely smooth and very clean. Now while the tests that you have conducted show extremely impressive results, I really must ask for a moderators input here. Showing this kind of material has the potential to lead to a potentially dangerous situation in the hands of someone that doesn't have the expertise to replicate this build safely.

Could a mod at least look at this thread, and provide some feedback. Again, its nothing personal, and I hope you don't take it that way, it just seems to be a safety issue in my opinion. My concern is purely sincere.

-Matt

Shadarlocoth said:

Have you ever thought our armor was a little bit on the flimsy side? Just does not have the effect you want. And what happens if a cop goes nuts at seeing an armored guy with a gun and does not know what halo is?

Click to expand...

Considering that the purposes of our armor is just for costuming, it doesn't matter if it's "flimsy" as long as it stands up to being worn at conventions and events, etc. Fiberglass reinforced suits are plenty strong for that.

Regarding a "cop going nuts", first of all, if you're going to be parading in public with a prop gun, it better have an orange tip to identify it as such. And even then, I doubt a police officer would just open fire the instant he sees someone in a Spartan costume (which I believe is what you're insinuating). Considering the circumstances you'll be in (most likely have onlookers and perhaps a friend or 2 as escorts) I doubt you will be considered as a threat. Maybe they'll come and investigate, but that's about it. However, that could change once they learn that your armor is actually bullet resistant and not just for fun.

This unfortunately comes to mind....

Here's a question I'm surprised hasn't been asked yet. How much money are you spending on these supplies? Don't get me wrong, it's an interesting and ambitious project. I'm just curious as to how much you're shelling out to make a "real" costume.

Well lets cover a few comments working with carbonfiber/kevlar/carbon nano tubes needs the same protection level IE respiration and gloves that fiberglass does also respiration is needed for sanding on the item as well. And don’t forget eye protection. I use my Msa 1000 gasmask ooo fun….Only upside it does not make you itchy like fiberglass... The only thing that really needs to be watched is if you are doing life fire testing. I just toss on one of my Vest incase of a bad time in donkey town.




Now as for the comments leading into the build they are for fun I don't really think anyone will build halo armor as a means to stop gun fire. Well besides me that is... but using carbon fiber or Kevlar instead of fiberglass would work as it is rather light if you did not use the onyx with massive strength.

Now as for the cop comment your right I have never had a cop bother me even walking up to me when I was in my COD costume with my scar out with no orange tip as in most states an orange tip is only needed when selling the item.

My cod costume is more ballistic than this will ever be... old pic’s of my old build I have a new one with the ITOV and 40mm build load out. Live fire with my Siaga 12 fun fun.




Now as for project cost really the chest plate that I shot up I would say 10 bucks in onyx, 10 bucks in carbon nano tubes, 8 bucks in carbon fiber, 5 bucks in Kevlar, so I used about 33-40 bucks in the chest I shot up. I will get weights later on them.

As for hole project I have picked up 10 yards by 63” of Kevlar at 150 buck, 10 yards of carbon fiber 54” at 230 bucks, 2 gallons of epoxy at 55 bucks, 1 gallon kit which is made of 2 one gallon part a and b of onyx at 94 bucks, Kevlar shears 46 bucks, 50 grams of carbon nano tubes 100 bucks, 5 lb of boron carbide 118 bucks, foam it V 1 gallon kit 86 bucks, flex foam it v, 1 gallon kit 95 bucks, epoxacast 650 trial 19 part A part b 101 fast 14.90,

no if your talking about the rest of the gear for the odst your looking at more I have a IOTV in black with IIIA panels which ran about 250, then rip stop flame retardant tactical uniform rand about 100 for pants and shirt, then elbow and knee pads which ran another 20, and Kevlar reinforced gloves add another 40, and a under armor flame retardant hood another 40 if I remember right. Then we would need to add in the daps in black that shoulders will be mounted 2 I have the ballistic inserts for that as well so looking at another 80 bucks there.

Of cause that’s not cover the cost of the armor or any molds that my be needed. Also the vast majority of this smooth-on stuff will be left over for later projects.

So raw supply looking at 1025 dollars about… give or take I also have dragon skin and brush on 60 if any other building is needed.
And another 530 bucks for costume add-ons not including the smg or pistol or knife from the live action film.
I’m guessing that the total cost for this project will be will into the 2-5k range but that is about the same as it cost for my Sith Stalker or for each set of my COD gi gear so really its no big deal.

Spitfire22V said:

Regarding a "cop going nuts", first of all, if you're going to be parading in public with a prop gun, it better have an orange tip to identify it as such. And even then, I doubt a police officer would just open fire the instant he sees someone in a Spartan costume (which I believe is what you're insinuating). Considering the circumstances you'll be in (most likely have onlookers and perhaps a friend or 2 as escorts) I doubt you will be considered as a threat. Maybe they'll come and investigate, but that's about it. However, that could change once they learn that your armor is actually bullet resistant and not just for fun.

This unfortunately comes to mind....

Click to expand...

I think your completely missing the tone here and taking this way too seriously. Nice project, whats the website you order your supplies from and would they happen to have kydex? I've been wanting to make a holster for my Glock 19.

M07Marauder said:

I think your completely missing the tone here and taking this way too seriously.

Click to expand...

I disagree, considering that threads consisting of armor for paintball/airsoft are frowned upon around here due to accountability/support issues of these projects being associated with the 405th, which as I understand is to be strictly for costuming purposes.

Don't get me wrong, I think this stuff is incredibly interesting and I greatly enjoy reading about it. I just don't think it's allowed, unfortunately.

smooth-on local seller, ebay elite-motors they have a wide range of fibers for sale kevlar-carbonfiber, sandblastingabrasives.com for boron carbide, Sun Innovations or US Research Nanomaterials for nano particals and nanotubes. US-research is cheeper by half on industral MWNT.

Spitfire22V said:

I disagree, considering that threads consisting of armor for paintball/airsoft are frowned upon around here due to accountability/support issues of these projects being associated with the 405th, which as I understand is to be strictly for costuming purposes.

Don't get me wrong, I think this stuff is incredibly interesting and I greatly enjoy reading about it. I just don't think it's allowed, unfortunately.

Click to expand...

Lucky for me I dont plan to use it for airsoft or pantball 8) I just want armor that is not going to be broken by the TSA every time they get there hands on it. And its really cool to say yes this is balisticly sound 8)... braging rights and all... If I wanted to play paintball I would use my COD millitary issued gear. I readed though the infraction list and forum usage rules and did not see it so If I missed it. Then its my bad. As for using it for real armor would be almost crazy as there are to many gaps and small spaces in the armor a Spartan would make alot more sence then a ODST.

You read* through* the infraction list and forum usage rules. <-- Not being rude, just trying to be helpful.

I find this to be quite interesting. if i ever got the money i would love to make my armor like this. just so when someone says jokingly who doesnt know anything about how lame my suit is and mocks it by saying "well can it really stop bullets?" i can truthfully reply "yes!" lol. but seriously it's informative especially since i had no idea what bullet proof armor was made out of.

As awsome as this is, even ballistic spartan armor would be bad to use out in the field, its acctually more clunky and bulky then in game. When i tested my chest piece with my shoulder and forearm pieces, i couldn't hold my shot gun prop correctly, let alone a reall weapon. lol I think a odst style armor would be better than a spartans, less bulky and easier to move, at least from what i have seen.

Marvelous said:

You read* through* the infraction list and forum usage rules. <-- Not being rude, just trying to be helpful.

Click to expand...

Sorry bit of a smart ass I will refrain from explaining my position and will just deal with build questions and build details.

holy mother... thank you for posting this.. if they moderate you its the lamest thing to ever happen in the history of spec guys actually trying to connect with the masses.. we have been planning a h.a.l.o. halo suit for a couple weeks now but your soo ahead of the win curve - Keep it up!

Trooper114 said:

As awsome as this is, even ballistic spartan armor would be bad to use out in the field, its acctually more clunky and bulky then in game. When i tested my chest piece with my shoulder and forearm pieces, i couldn't hold my shot gun prop correctly, let alone a reall weapon. lol I think a odst style armor would be better than a spartans, less bulky and easier to move, at least from what i have seen.

Click to expand...

if your going through the trouble to create that level of MJOLNIR inspired armor (hypothetically of course) then certain things are going to need attention. the loss of mobility can be augmented with artificial muscle groups - carbon nano fiber can do more than just stop bullets or make your car look boss. so far as the weapons go if your at this calibre then standard weapons shouldnt be assumed; electromagnetic weapons might be though, or perhaps a more traditional composite firearm such as the G11. Now, if you cant live wo that psg1 (which is totally understandable) or what have you, then optimizing the structural physics of your support shoulder / arm with MATLAB would be a days work w the right technicians help. hell if you modded the butt of a PGL65-40 to actually synchronize with the armor you wouldnt even have to optimize.. or go for the gold and just put a mk19 on the shoulders - the posibilites are endless.. The real killer would be heat, so ac is - er, would be a must, as well as a formidable hydration pack. add an nvidia tesla to run the ai motion tracking / threat id scripts, ac, nano muscles, nods (or thermal whatever floats your boat), ground effects, etc - and your in business.. am i forgetting nething? oh, the chem mask might need some heavy modification to fit the helmet of your choice.. I prefer EVA wit a big HUD.

Now before the legality of the following gets out of hand:

Spitfire22V said:

Considering that the purposes of our armor is just for costuming, it doesn't matter if it's "flimsy" as long as it stands up to being worn at conventions and events, etc. Fiberglass reinforced suits are plenty strong for that.

Click to expand...

Spitfire22V said:

I disagree, considering that threads consisting of armor for paintball/airsoft are frowned upon around here due to accountability/support issues of these projects being associated with the 405th, which as I understand is to be strictly for costuming purposes.

Click to expand...

Shadarlocoth said:

Lucky for me I dont plan to use it for airsoft or pantball 8) I just want armor that is not going to be broken by the TSA every time they get there hands on it. And its really cool to say yes this is balisticly sound

Click to expand...

lets consider that a couple HALO fan films are being made, (hell one of those industrious groups even built a friggin drop pod); so to reason that an ODST project of great magnitude is in the works by trained professional paratroopers in support of that project would not be out of question. Therefore, a physically sound costume would need to be constructed out of realistic materials..

As Shadarlocoth mentioned above he is not using this prop for paintball or airsoft - a major infraction round these parts.. ; he is using it for bragging rights.. so lets say others copy his design for use in the movie, or another movie, for the explicit purpose of creating a realistic airborne cinematic .. then the suit he is creating and all subsequent suits by the same design are in fact: COSTUMES. I will mail you a copy of my dd214 in the morning should you wish to challenge the professionalism in that area. Also, it would be realistic that a suit of that calibre would be used in demolition sequences for the movie so as to portray accurate combat / create realistic battle damage on props.. Lucky for our cenario that i also carry the 21b identifier from my early days at Bragg and served as a backup demo guy for our local police department.

I can now be established that a real ODST suit of armor would be needed for the aforementioned cinematic display; and birds are always standing by at Pope, or Pittsburgh, or DM, doesnt matter - wherever jumps are had. If you couldnt tell, i really really dont want to see this thread die. i would like to continue learning about this man's extraordinary process so as to make really kick ass costumes for a Halo fan film, using methods that i have been trained extensively in so as to be safe...

Thank you,

- Jaeson

p.s. thought you might want to see my own project based off a very similar construction method

Haha, this is an awsome build, bullet proof halo armour, now you can add some real battle damage with out worry of breaking your suit

Necrogenesis said:

lets consider that a couple HALO fan films are being made, (hell one of those industrious groups even built a friggin drop pod); so to reason that an ODST project of great magnitude is in the works by trained professional paratroopers in support of that project would not be out of question. Therefore, a physically sound costume would need to be constructed out of realistic materials..

Click to expand...

You forgot to make the causal relationship clear between involving expert advisors and creating actual "physically sound" equipment. They had advisors when they filmed Armageddon - that does not mean that a single prop in the movie was actually functional. You can also create realistic looking battle damage without creating real equipment.

so lets say others copy his design for use in the movie, or another movie,

Click to expand...

Lets say a child copies it! Most likely with a profound lack of understanding and knowledge, and most likely replacing some or all of the materials with cheaper or more easily available ones, just like we're seeing it all the time on the forums. He'll play with it, feel totally cool and at some point daddy's gun might enter the game. And someone might end up dead. What then?

I doubt that this is a legal issue, at least for the one who's posting it here. But it definitely is an ethical question. How far do you want to go showing things, especially when you are very aware of the fact that a lot of young, irresponsible people are going to read it? I think it's interesting and I'd love to see more - but I also think it's crossing the line.