DIY Armor Projects

You have reached my experimental / concept ballistic armor page. I am interested in bullet resistant armor but have found that commercially available armor can be expensive or difficult to obtain. Many armors use exotic materials or have very high tool requirements, putting them out of the reach of most experimenters. My primary goal is to explore how low-cost, expedient armors can be made at home with commonly available materials and tools.

Armor Experiments


"Bullet-Proof" Laminated Glass
Blog Post | Construction/Results Video 
Materials Used: 1/8" Acrylic and Polycarbonate Sheets, Liquid Nails Adhesive
Construction: 2 layers Acrylic, 1 layer Polycarbonate, glued with clear liquid nails adhesive, left to cure without clamping
Verified Stops: .380 Auto FMJ, .38 Special JHP
Thickness: .26"
Other Features: "One-way"armor - will allow bullets to pass from non-threat side.

Fiberglass Armor Panel
Blog Post | Construction Video | Live Fire Test
Materials Used:  Fiberglass Woven Roving (18oz/ square yd), Polyester Laminating Resin
Construction: 23 layers of Fiberglass WR cloth soaked in 12 oz Polyester resin, clamped between wood plates while curing
Verified Stops: 9x19mm FMJ
Thickness: .343"
Weight: 3.8 lbs 
Size: 11" x 13"
 Other Features: Multi-hit tested with 9mm FMJ

Ceramic Fiberglass Tile - "Shard" Armor
Blog Post | Construction Video | Live Fire Test
Materials Used: Bathroom Ceramic Tile, Fiberglass Woven Roving, Polyester Resin
Construction: 1 layer of WR wrapped  around 4.25" x 4.25" x .25"tile, gives 8 layers on back.
Verified Stops: 9x19mm FMJ
Thickness: 3/8"
Other Features: Size dependent on tile selected.


Porcelain/Fiberglass Standalone Curved Pistol Plate
Blog Post | Construction | Live Fire Test
Materials Used: Porcelain Tile, Fiberglass Woven Roving, Polyester Resin
Construction: 2 layers WR frag, 1 layer of 30 1.9"x1.9 tiles, 10 layers WR spall liner. Saturated with 8oz of polyester resin and clamped in a curved mold. Baked to cure in hotbox @ 90 degrees.
Verified Stops: 9x19mm FMJ
Thickness: .5"
Weight: 4.0 lbs 
Size: 10 x 12"
Other Features: Plate is curved in one dimension to fit in plate carrier, tiles have gaps of 3/16" for simple manufacture (tiles are purchased in this configuration) - this does not affect performance

Porcelain/Fiberglass Standalone Curved Rifle Plate (coming soon)
Blog Post | Construction Video | Live Fire Test
Materials Used:
Porcelain Tile, Fiberglass Woven Roving, Polyester Resin
Construction: 2 layers WR frag, 2 layers of 30 1.9"x1.9 tiles, 1 WR inter-layer, 10 layers WR spall liner. Saturated with 10oz of polyester resin and clamped in a curved mold. Baked to cure in hotbox @ 90 degrees.
Verified Stops: Pending Test
Thickness: .75"
Weight: 6.0 lbs 
Size: 10 x 12"
Other Features: Plate is curved in one dimension to provide comfortable body fit in an armor or plate carrier.No gaps between tiles, the seams between the tiles layers are staggered.