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Could you not contact cement 'pickle barrel' plastic to the closed cell foam to turn soft armour into a hard plate feel? Heck, cut out two plates and use the foam as filler in the middle for added realistic thickness.
Those barrels are high impact plastic so they can take a lot of abuse, are cheap, easy to cut with cheap jigsaw, and are moldable with a torch or oven.
Oven warmed, they can be molded to your body shape...remember to cover side with wet towel first....hssssss!
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