Part 6 – Ballistic Arm Protectors

Hard armour: these consists of two parts for each arm and can be made from flexible kevlar composite plates (lvl IIIA) and applied on top of your Damascus FX1 – Flexforce lower arm protectors (see blueprint and remember to remove the hard elbow and large plastic layer/shell as they are too bulky).

Requirement: Damascus FX1 – Flexforce (riot gear to provide blunt trauma protection and a base/fundament for applying these parts)

Difficulty level to create: EASY (it is suggested that you create these as they are not possible to acquire on the open market. Please see my prototype blueprints).

Coverage area: from wrist to elbow.

Use the arm piece from your Damascus FX-1 FlexForce riot gear and simply apply the pieces of flexible Kevlar composite as referred to on the blueprint. This must be secured using hook/loop and nylon straps.

Aproximate cost: 30-50 Euro (if you have already paid for a riot gear system and other materials).

Hours of labour required: 7

Part 7 – Ballistic shield (level III)

Hard armour: these consist of two kevlar composite panels, one piece of polycarbonate plate (5 mm thick) and is basically screwed together using 8 screws.

Requirement: ballistic composite panel (2 pieces - 40 x 55 cm or whichever size you desire + 1 piece of polycarbonate (plexiglass) in the same size)

Difficulty level to create: EASY (it is suggested that you create this item as they are very hard to acquire on the open market. The ones available are quite heavy and very expensive. The weight should not surpass 5 kg for a level III shield with multihit capabilities.

Some ballistic shields are for sale to law enforcement officers/organisations. Unfortunately, they are very strict and require documentation that you are an official “system protector”.

These shields vary in weight but you can get them from 7-30 kg. They are quite expensive and the most inexpensive item I was able to locate (weighing 7 kg) costs 800 USD.

Fortunately for us, it is quite easy to create a suitable, low weight ballistic shield. Simply use a part of the flexible ballistic composite plates/panel you ordered (level IIIA) and cut the material in the appropriate size. I chose 55 cm x 40 cm so it would fit my armour cache (Pelican 1620 case) which I am soon going to dig down together with all my other armour before I start my “weapon acquirement phase”.

When you have cut the 2 plates/panels (40x55 cm) and ordered your 5 mm polycarbonate (PVC) plate from your nearest plastic-composite-supplier simply drill holes and screw the three plates together with your polycarbonate plate toward you. Create three nylon straps (2 pieces of 1 inch - 2 layers of nylon straps sewn together (28 cm) and one piece of 2 inch – 2 layers sewn together (35 cm). See blueprint template. You then apply the straps on the screws on the backside of the shield and fasten with matrixes. Two of the straps will be placed so that it will fit your arm while the last strap will be placed on the lower right to work as a support strap/handle. You can also apply a padded carrying strap so that you can hang the shield on your back while on the move. Use adhesive hook and loop material on the front side to apply insignias etc. and use a black, spirit based permanent marker for the metal colored screws and other inconsistencies in color (shield should be black like all other armour).

Congratulations, you now have a descent and lightweight ballistic shield (level III, 4 kg) with multi-hit capabilities for less than 100 Euro (50 Euro for polycarbonate plate, 15 Euro for carrying strap, 10 Euro for screws/matrixes. Not counting the 700 USD cost for the original ballistic panel and the fees for the nylon straps). You may also apply razor sharp objects on it to act as a deterrent or emblems according to your specific mission.

End note: I tried cutting the ballistic panel (into 11 pieces for the various armour pieces) with my electric jig saw. My saw is of poor quality so I had to go to a work shop (furniture cutter) to have it cut properly. This service cost 80 Euro. Be careful doing this as the cutting patterns would indicate that you are creating ballistic armour pieces. In retrospect, I found out that I could cut the ballistic panel by applying pressure and using sawing motions with very sharp objects.