Hidden Armored Vest

This vest was made using a cotton-canvas that was preshrunk and left natural colored. The plastic plates were cut using a RotoZip^® though a jigsaw or similar could be used to similar effect. The plastic is from a 55 gallon drum that had been discarded and then cleaned before use by myself. I incorporated the structural ridges in the barrel into the cutting design to strengthen the plates. After cutting the plates, I filed and sanded the edges to afford a smooth edge to lessen friction with the canvas. It was then placed in an over at 450°F, placed on the body using several thick towels to act as a heat shield and then cooled under water. Use a well ventilated area when heating the plastic as fumes are given off and use oven mitts to protect the hands.

The Plates were marked so as not to misplace their order for later. I cut out two similar vests of canvas. I did the inside out method of sewing where you sew in reverse and pull the material inside out into the correct position. I left the bottom hem open to insert the plates later.

The plates were laced though holes I had made using 550 Paracord in a cross pattern. These were then inserted into the vest into their proper positions. I then used a tailor's chalk to mark the lines between the plates [vertically]. I removed the plates and stitched over the lines. This keeps the plates in their rows during use. I reinserted the plates and sew the bottom hem closed. It is important that the bottom of the plates at the hemline are very round and smooth [sanding] so they do not tear through the hem! I then marked where I wanted my huge brass rivets to be placed, one at the near to or each plate and also at the bottom of each plate. I drilled through the material and plates, inserted a silvery washer and brass rivet on the front side and a small rivet on the back where I peened over the end of the rivet. Next time I would look for or make decorative washers for the front side.

Spots I had missed when sewing were hand sewn over and then the straps were placed as needed with Quikie Rivets, straps and buckles. My straps are on the left side, not like shown in the drawings. I am presently suspending a leather backed lamellar shoulder system to deflect shoulder blows. My next project is the gambeson with mittens.

Use under a jupon or any Surcoat 12-13th Century without fear of folks seeing the plastic or having to endure the weight of mail. Digital photos coming soon!