Improvised Counter-I.E.D. Armor - Part 2 |
Overview
As a followup to an article in GBPPR 'Zine #33 on improvised armor, this idea is based on using old Ceramic Dual In-Line Package (CERDIP) integrated circuits, and even some old computer CPUs, as "hardplate" armor. The idea is that the hard ceramics which are used for the cases on these integrated circuits, can also be used to deflect any incoming shrapnel. Does it really work? I have no idea on how to test this stuff in the real world... But, it is fun to mess around with. The hard, but brittle, ceramic cases to tend to break into a million little pieces on impact. This might be good, as it is dissipating energy, but on the other hand, you are making even more shrapnel.
It would probably be a good idea to wrap this entire contraption in several (hundred?) layers of Kevlar material. A good source for large rolls of Kevlar material is from homebrew aircraft suppliers. The Kevlar material does appear to need a special set of shears to cut through it, though. Wicks Aircraft Supply, www.wicksaircraft.com, sells different types of Kelvar material at around $18 per yard:
Excerpt from a Wicks Aircraft Supply catalog:
Aramid fiber, one of the newest and most far-reaching developments of textile research, has the highest strength-to-weight ratio of any commercially available fiber. Kevlar gives airplane builders a significant design edge by allowing designers and builders to save weight and increase strength in their aircraft. Kevlar aramid has an excellent combination of weight, high-strength, outstanding toughness with abuse resistance, and stiffness, that can be put to good use in the production of light aircraft. Kevlar fibers have a density 43% lower than fiberglass and 23% to 30% lower than the various graphite and carbon fibers. Kevlar 49 is 2.5 times as strong as the commercially used E-glass and greater than ten times as strong as aluminum on a specific tensile strength basis. Kevlar has good chemical resistance and meets FAA flammability requirements as it does not melt or support combustion. It provides a less rigid structure, with even better damage resistance. Composites of Kevlar are more durable than those of fiberglass and carbon because the aramid fiber provides superior resistance to damage, vibration, and crack propagations, as well as excellent fatigue resistance. Although Kevlar has many advantages over conventional fiberglass weaves, it is very difficult to cut. Special scissors have been developed to facilitate cutting. These scissors have a wear-resistant coating which is metallurgically bonded to the steel substrate. The coating will not chip or peel off and can be sharpened.
Pictures & Notes

Overview. Four hard drive platters are on the left, and several ceramic packaged CPUs and integrated circuits are on the right. The CPUs are old Intel Pentiums and 486s. These seem to be the best choice, as their ceramic cases are physically larger.

Close up of the CERDIP integrated circuits. You'll need to scarf up old circuit boards at ham radio swapfests to get a large assortment of CERDIP integrated circuits. I found old AT&T telecom circuit boards to be filled with them.

Start like we did in the last issue by epoxying two hard drive platters together. Also do this with the other two platters. The idea is to sandwich the ceramics between the two new dual-platters.

You'll need to grind down the metal pins on the CPUs and integrated circuits. Use an angle grinder with an abrasive wheel attachment. Don't push down too hard, or the CPU will snap in half.

Intel Pentium CPU with the pins ground down. You may want to also grind down the little brazed "cap" that protects the actual CPU. This is the high spot in the middle with the letters printed on it. This will also help the CPU to sit flat when epoxied to the drive platters.

You can snap the CPU into smaller pieces to fill the platters. You'll want to grind down any sharp points when used for "real world" applications.

Epoxy everything together like so. Total weight for this plate was 6.15 ounces.

Close up view. You'll want to make sure that the ceramic cases are all level. That will be a problem if you mix and match CPUs and integrated circuits. Grinding down the sharp points is also a very good idea, but will take awhile.