Looking for an ABS alternative

redkraytdragon

Active Member
Hey everyone,
Well I decided to post this topic in the costumes area because I vacuum form ABS for costume armor parts. However, recently with the rise in cost of ABS going through the roof, it has also started to affect the availability of it for my local supplier (I'm in Albuquerque, NM). I find myself constantly in need of the smooth stuff without the yucky haircell texture that they put on one side. I have been resorting to using the 1/8" not only because it is tougher but because the haircell won't show through on the other side (been using black because white is harder to get nowadays). But whenever I ask for the ABS in white, .090 thickness with smooth on both sides, they tell me that they can't get it anymore or they won't be able to soon (which is the same stuff that most Stormtrooper kits are made from, among other popular SW costumes)

In the discussion with my supplier about this, he recommended a thermoforming plastic called Kydex. From what I understand this material has acrylic in it as well. I have no doubts that this stuff will form well and he informed me that it is pretty tough and readily available in all the thicknesses and colors I would need.

My question is: Has anyone here used it or had any experience with it? How well does it sand and take paint? And also very important, how well does it take adhesives like E6000, Plastic welder, bondo, etc. The reason I ask this is because he had some sample pieces that I held in my hand and I was skeptical about how well this stuff would work for an armor application. Any info would be great and any info about any other plastics would be great as well. Thanks everyone.

P.S. I've also heard about PVC type 2 but was told that it is not UV stable, anyone know anything about this plastic either?
 
I know several fellow SCA fighters who have Kydex armor (3/16" or 1/4" I believe) which has served them well on the field. It's plenty durable, but I can't say much about adhesives or paint on it, since it was riveted.
 
I started doing a little searching, and the Kydex company actually has more technical data about the material than I even cared to sift through. :lol If you're more patient than I am, you can probably find the information you need (and then some).
 
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