What Kind of Rubber for molding Armor

[Rikarus]

I am considering making some molds for SST Armor, I have done the items up in cad, and am working on making them a reality. But what type of rubber is used to pour into the molds and be flexible yet durable.

The originals had a rubber shell and were filled with some funky foam, I am thinking solid rubber would be more durable, and less subject to some of the damage that screen used stuff has.


Thanks for any help/input!

 

[TK648]

The molds for the SST armor were vacuum formed and the skin of the armor was a two part flexible urethane followed by a two part urethane foam, after the skin was made
then the foam was pored on top of the urethane skin into the mold, which was then was sandwiched with a sheet of acrylic on top to make the foam spread flat and evenly thru the piece.
I tried using the foam once and that was a nightmare, so I found foam sheet
that had an adhesive back and stuck that into the flexible urethane skin.
I also had all of the aluminum plates that hold the straps on made to the same size as the screen used armor.
Solid rubber would also be a lot heavier, and wearing the armor made with the foam is still like wearing a upper body cast
Hope this helps

Here are some pics of my SST armor molds and the wooden bucks used to make the vacuum formed molds.

Screen used armor is on the top of the pic and the armor I made is underneath

my vacuum formed molds

these two bucks make up the shoulder armor

 

[Rikarus]

WOW! That is incredible work!


I was thinking I might be able to luck into some form of light weight rubber, a single pour item being more of the skill level I am at so far.

Did you make many sets, or jsut the one?