Make Aluminum Foil Armor




About: I'm just a crazy OT student that dreams of changing the medical industry one DIY at a time. I started out here as some crazy middle-schooler with ADHD that was bored and wanted to make the most random things...

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

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!!

Step 2: Getting It Ready

First you need to crumple the aluminum into a compressed little ball. Notice how small I made a foot of foil into, about an inch and a half ball!

Step 3: Compression

In this part you compress the foil ball. A good method is putting the ball on a flat surface(tile or cement preferably) and slamming your foot on it really hard(but you need the shoe on). The better way after you squish it is to take the mallet and hitting it. My ball after it was squished by my shoe I used the mallet and it went from half an inch to 3 millimeters. This was not listed but you can use a vice too.

Step 4: Product

You can use this for armor and things like that. It really lessened a knuckle punches hit. I'm working on a vacuum former to make shells to go around the plates. I'm going to attempt to make paint ball armor out of it after a few tests. The rest is still to be updated, check back soon.......

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    94 Discussions


    4 years ago on Introduction

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


    11 years ago on Introduction

    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.

    17 replies

    Reply 10 years ago on Introduction

    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


    Reply 7 years ago on Introduction

    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.

    John SmithTheScientist

    Reply 11 years ago on Introduction

    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!

    x z i tJohn Smith

    Reply 9 years ago on Introduction

    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

    GraceB6x z i t

    Reply 4 years ago on Introduction

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

    daelansJohn Smith

    Reply 9 years ago on Introduction

    wait, aluminium, isnt that the er thing on the table. the periods table or whatever.


    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!


    Reply 4 years ago on Introduction


    "[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. ;)


    Reply 10 years ago on Introduction

    Actually, many (Sane? Smart? Different? Yeah thats it..) Americans do use aluminium. Lest, I do... -RoAr


    Reply 9 years ago on Introduction

    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?