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No, you're thinking of Zylon. Zylon has greater strength, but isn't as effective over time. Actually, studies are showing that Kevlar is stronger over time.
thin vests might stop the bullet but you still get the effect of the bullet even with police vest it bruises and hurts. not sure on plates . so not perfect but better than a shirt
you can get yards of Kevlar material online easily. using felt as an internal liner and an external compression layer to soften the blow you could do it. I would take a watermelon put the felt on it, put the layers of Kevlar on it, put your compression layer on it, then shoot it with whatever iiia iii or iv caliber from about a foot away. if successful I would replicate and add double the layers of Kevlar.
The only reason I would give such foolish advice is that I want to do the same thing for the doors and back of my pickup as a bug out vehicle. I have a professionally made iiia stealth vest. I want to look innocent while extracting through check points.
Buy your vest and make anything that you want to save that they wont sell you.
Also I have a pair of tactical pants where they have a knee pad that's replaceable. I am going to make a pair of iiia knee pads that wrap around. a leg wound is one thing but a knee injury is for life.
I recently read an article about how you can make Boron Carbide, (which is what they use on tanks, and is much, much stronger than Kevlar,), from an ordinary cotton T-shirt. If you have access to an oven that can get about 1300 degrees fahrenheit, that could be a relativity cheap way. http://news.discovery.com/tech/gear-and-gadgets/t-shirt-body-armor-tank.htm
I have personally dealt with a company called AR500 at www.AR500.com
They are great. Their product are legit.
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