Picture of Make Aluminum Foil Armor
OK it has alot more uses than its name, like scales, plates, and as I said ARMOR. NOTE: This instructable will have alot of updates so check back every little while.

Step 1: Material list

Picture of Material list
Things you will need to make your "foil thing":

1. Foil (of course)
2. Shoe and foot
3.Rubber mallet (better alternative to a shoe)
4.Hand with good grip
5.Super strong assistant(preferably a monkey) Hey! where'd he go!!
coleblaze4024 months ago

that seems more reasonable

coleblaze4024 months ago

How about you just strap a pillow to yourself and jump of the empire state building

how much does each piece weigh? (presumably that would be the practical use of it over steel!)

cool idea for paintball armour too :) I admit I was originally thinking "what's aluminium armour going to stop?" but it's sure stop paintballs (or BB's for that matter... although they might embed)

my only criticism of your instructable is that a couple of the pictures could do with you using a flash (or take it outside during daylight)

oh yeah, and it's "Aluminium" not aluminum! silly americans! ;-)

before people jump on that, I know both spellings are considered appropriate, just nobody else in the world (especially not the scientific world) uses it.
hey polocks spell bad to!
hehe "polocks spell bad" The statement is proof in itself. lol Mr Smith is right, even though aluminium was the original term for it. Lazy American slange hits the books and becomes official. We're good at that kind of stuff. lol

hay, me is smart, two!

(those mistakes, including homophones, are intentional)

The name was coined in 1808 as "Alumium" by English chemist Sir Humphry Davey. He later amended it to "Aluminum", which is how the Americans say it.

In 1812, British editors further amended it to "Aluminium", and it remains the version the British use.

Thus, nobody uses the original word, but Americans use an older version than the English.

"Aluminium, for so we shall take the liberty of writing the word, in preference to aluminum, which has a less classical sound. ["Quarterly Review," 1812]"

Silly Brits, always gotta sound snooty even when a Brit coins a term.
In the UK and other countries using British spelling, only aluminium is used. In the United States, the spelling aluminium is largely unknown, and the spelling aluminum predominates.[12][13] The Canadian Oxford Dictionary prefers aluminum, whereas the Australian Macquarie Dictionary prefers aluminium. The spelling in virtually all other languages is analogous to the -ium ending. -Wikipedia Another cool thing would be to cast aluminum plate armor for paintball/airsoft...hmmm, I need to fire up my foundry!
its the english language that is messed up also, yea do the foundry. i did it, its a lot of fun, but it takes lots of time and some money
GraceB6 x z i t6 months ago

Oh, and you're not speaking English now? What language is "also"? or "fun"? lol

wait, aluminium, isnt that the er thing on the table. the periods table or whatever.
GraceB6 daelans6 months ago

periodic table

no, it's not "er", it's "al" after alumin... and it's called the periodic table.

(note: alumin... is what I used to not restart the debate up there about alumin(i)um foil) 
If you want to feel super superior, call it alumium. That was the original word, it was then changed to aluminum, then again to aluminium.

The US and Canada both use the older* aluminum than the more recent British aluminium.

*Four years older is still older!
ur to smart! my brain hurts now!
That or you're too dumb. (lol just kidding)


"[oh yeah, and it's "Aluminium" not aluminum! silly americans!"]


oh yeah, and it can be "Aluminium" OR aluminum! silly TheScientist! ;-)

Oops, typed that out before I read the last part. I just thought it was too good to throw away, so here it is. ;)

Actually, many (Sane? Smart? Different? Yeah thats it..) Americans do use aluminium. Lest, I do... -RoAr
temp PKTraceur6 years ago
americans say TIN foil. I really don't know why.
daelans temp5 years ago
about that, i was at a camp one time, like summer camp, and there was a theme thing for a day and it was knights and armor and swords and bows and stuff and there were these people who made it out of tin foil and whenever we said tin foil theyd flip out and be like "NO ITS ALUMINUM FOIL" and crap, whats the difference?
temp daelans5 years ago
Tin was used a long time ago. That's about it.
me835 temp6 years ago
its because before aluminum was practical, tin was used instead. i may be wrong about the 'practical' thing, but the tin-before-aluminum thing is correct. the name just stuck
I think people say tin foil for the same reason they call tissues Kleenex. It's just a brand name their use to hearing. Like you said back then they only used tin foil.
i know another one of those! Dremel!
Lego man (author)  TheScientist7 years ago
Yeh it was dark outside so I couldent use daylight. but I will in my updates.
curvy772 years ago
(sigh) so many people make good instructables for this, but not one for how to make armor from liquid aluminum to mold casting. T-T. O well, let trial (and major error) commence!! btw great instructable.
About how much aluminum foil do you need to make scales/armor for the whole chest and back? (Covering All Surfaces)
how much aluminum foil if a blacksmith could a blacksmith smith if a blacksmith could smith effective aluminum platebody

btw there are now whitesmiths bluesmiths (although there are blue smurf) what am i talking about i forget
Clayton H.6 years ago
Yea, but can it stop a .22 centerfire cartridge traveling at 2400–3000 fps Hmmm?
Ok. The .22 cartridge is a RIMFIRE cartridge. There is no such thing as a .22 CENTERFIRE cartridge. Oh yeah and pktraceur, the smallest bullet is the 2mm pinfire round. It packs about as much punch as a fairly sluggish airsoft gun.
first centerfire .22 rounds are out there
second they aren't that common
third rimfire.22 round are extremly common
fourth give me some homemade armour to stop a 357 sig
fifth buy a loom and lots of kevlar fishing line (braid)
sixth get to weaving
seventh if you found this educational and comical press 1 now

Your understanding of rifle calibers is incredibly deficient. The .22 centerfire is probably the most common rifle round in the world.

Educate yourself, man.
Dude, it's compressed food-grade aluminium, WTH do you expect? (Maybe If I add a steel plate...) -PKT
yes I know, I was seeing what kind of awnser Lego Man would give.
Lego man (author)  Clayton H.5 years ago
wow, i just found out you commented :S, im sure it cant stand it, considering thats a bullet (right?) well now im not sure, i dont really have knowledge of ammo and such :(
Yes, that is pretty much the smallest caliber bullet. .22 of an inch in diameter, each one about an inch long.
And enough power to travel a couple miles in the air, if fired at the proper angle.

It isn't even close to the smallest caliber round, though. Smallest commercial caliber was a .11, but it was never popular.

.17 is a somewhat popular caliber for varmint hunting, because you can get some very high speed (4000+ fps) rounds, though the .22 Remington is still more popular for the purpose.
its sure as hell not gonna stop a 22.
 I came up with the idea before, a year before I joined instructables (which was also 2008). So, I never got to post it here. Too bad my manufacturing process is very inefficient. Estimate how many plates you can get out of that with one roll. The no. of plates you need divided by how many plates you can get out of 1 roll equals the no. of rolls you need for your body armor. If you don't understand, look below:

z=no. of plates needed
y=no. of plates possible w/ 1 roll of foil
x=no. of rolls of foil needed

x / y = z
You said the formula correctly but you didn't write it out correctly - you switched Z and X.

Given your legend, it should be z / y = x
*1 year later* lol, I can see that... Although a tip, don't comment on extremely old comments, like mine. Not a lot of people could remember what they've posted on a certain instructable after a few months (2 months?).
quetip14 years ago
might I suggest sticking a needle about a centimeter from the top and thread it together to form this "armor/scales" you were speaking of. this is probably the best approach seeing how as the idea of flexibility is compromised when using glue of any sorts and tape makes it more fragile.
howdyboy25 years ago
just wondering , what is the point of this in paintball were you are trying to keep paint from busting on you . I think this would be better suited for the airsoft section . A good version of this would be foam plates or a cloth , something that would be springy or impact dampening to prevent paint busting
could always roll a car over it
jakezcop7 years ago
ooo metal discs! is there a good way to ape it other than moulding?
ape it?
Lego man (author)  jakezcop7 years ago
Other than folding I can't think of anymore. A lot of practice and patience, it is fairly hard.
could you make large pieces and then saw or cut it? or wokuld it just fall apart?
You could but you should hit the sides were you cut it again to seal it shut and such
Lego man (author)  camocam6 years ago
hmmm, never thought of than, Thanks for the idea, im gonna try that and see how it works :D
how do you attach these together to make armor?
Lego man (author)  yellow elephant7 years ago
Yes i believe so, i was thinking of drilling holes and sewing them to a shirt. You can try if you want. (And Calvin rules but I like Hobbes better.)
lol? random much?
Pshaw. Hobbes, FTW.
Hobbes pwns.
if your making armor i wouldnt use thread i would use a very thin pliable wire. i dont know about where you live but by me i can either go to a gardening store or a craftshop and get a roll of thin green wire
8doug8 Lego man7 years ago
Hey lego man remember me well i was the one who told you about that so you should give me some of the credit
Lego man (author)  8doug87 years ago
I shall, I think I will do your way and my way to help that point or do it your way and give you the pics for your instructable.
8doug8 Lego man7 years ago
That'd be great, but what is the difference between your way and my two ways??
It's a packaged deal, man. You can't have one without the other. It just wouldn't be right.
Lego man (author)  Grey_Wolfe7 years ago
True, Very True...
Will it hold up decently to; lets say, a boffer sword? I really need a cheap alternative to going and purchasing 18 gauge copper sheeting to use as bootleg platemail.
lol, thats what i was here for, lol again.
For boffer swords? Buy some 20-22gauge steel plate... Scratch that, for boffer swords? Hardened leather.
I dunno, i would make it a lot more better than he does, try folding the foil together flat and maybe even layer aluminium can into it. My father works at a place where i can get get free sheet aluminium though, i've already made a whole body armor set from it using only a block of wood, an anvil and a ball pein hammer.
Lego man (author)  Mr Mild Mannered7 years ago
You mean as in a foam weapon?
Yeah, LARPing is what I do (Live Action Role-Playing), and I need some cheap 2 point armor that will withstand a day of traipsing in the woods, finding people and holding them ransom to their respective clans.
Lego man (author)  Mr Mild Mannered7 years ago
It stands up to a hammer so it should stand up to foam. It all depends on how you put it all together.
alright, then I shall me mr aluminium.
8doug86 years ago
hey Lego man if you do end up using my method to make the armor please right a note in there saying that i thought of it. sorry about being so nosey but it would by nice to have some congrats. if you don't mind you could just right at the end something about me not being able to use mine do to insuficiant pictures. please give me some feed back and we can talk about this.
ArmChairQB7 years ago
Do you have a link on how to make a parachute from tissues?
Lego man (author)  ArmChairQB7 years ago
Sweet I should try that.
flaresam7 years ago
Guys! I tested it, it stops knives!!!!!!! WOW COOL!!!!!!!!
You Could take a nail and use it to hammar holes in the ends, then take paperclips, bend them into little keychain loops and link a bunch together to make some armor. i like your idea and the instructable is so easy to read.
or somewhere on this site theres an instructable on how to rivit things togeather with nails... i like it...
minimidget7 years ago
I definitely consider myself an aluminum foil master (I've made whips, knives and other weapons with it. Very effectively I might add) and I have a few ways to ensure it is stronger, and more dense. Rather than balling it up, fold it up a bunch, compressing it after each fold. It takes longer, but is very much worth it. It is also a lot more malleable, so you can make things more easily. Also, it will be thinner, but a lot stronger. So you could disguise it better, like under clothes. I don't mean to come off as arrogant (I know I am, I'm really sorry about that) but I definitely have tons of experience with aluminum foil.
How do you make whips out of it?
mini midget would u care to enlighten us by making an instructable on these knives of aluminum foil
Lego man (author)  minimidget7 years ago
Thanks, I'll try that next time!
wazupwiop7 years ago
you could use a press to squash the foil
Cool! How hard is it? Do you think it could bruise somebody if I threw it at them? Nice Instructable by the way.
definitely I am in the process of making an Instructable with these only mine are much thinner(when I say in the process I mean I'm done but I can't find my camera so I can't put it out yet) any way I threw it like a frisbee at a wall and put a dent in it.
I would imagine so. It is just a chunk of ordinary aluminium. The difference is that is wouldnt be quite as dense unless you beat it enough. But maybe he did?
Use a 6 ton Hydraulic car jack.... That gets lots of things thin (especially soda cans) :P
haha french, try a 100 tonne rim press, makes a can into foil...
Haha fun :D
Lego man (author)  microman1717 years ago
Aluminum is very light and it takes a long time for you to make it heavy enough to bruise someone. My friend tried to make one to bruise somebody (He wanted to throw it at another freshman) and the thing was huge! It was so big he decided not to throw it.
lucky frosh...
i think if you made a thick enough one and it would probly bruise if it wasnt so thick too
8doug87 years ago
I made an instructable on paintball armor using your method check it out at "paintball armor"
jakezcop7 years ago
its not raely armor, But! i think u could pund out bigger circles or sumtin, then rivet them to geather to make a chest plate and small ones for gountlets, yay for protection and destruction!