I was thinking of an armadillo stile armor made of kydex which is the same stuff my knife sheath (yes that is my knife and its my baby i fuckin love that thing) is made of, and it has proven to be vary strong. its deffently bite proof and the best part is it can be molded into any shape so making armor that fits right will be easy especially if you find a manufacturer (which i have but unfortunately i dont have the funds to have anything made). And to hold the armor together i would somehow mount it on denim for flexiblity instead of bolting the scales to eachother.
Kydex is a strong Polymer. I've used it to make some pistol holsters. Fobus, Blackhawk Serpa and Uncle mike's are making awesome Kydex holsters and accessories. The problem I see with Kydex is that in a sufficient thickness to be useful as armor it is stiff. It can be molded with a heat gun or and oven. I use an old electric oven I got for free to work my Kydex. I think in order to make it useful as armor you'd have to layer it , like you said, Armadillo stile. The panels would have to be flexible so they wouldn't be ecure. Kydex slapping against Kydex will make some noise especially if you're on the run.
Other then that, it is lightweight and tough and would make a good armor. Maybe a backer of cloth glued to the underside would kill any noise...
That's what i was thinking, putting the plates onto/in between a layer of denim to hold it, also i wasn't gunna have the kydex be too thick i was thinking about the same thickness as my knife sheath because it has proven at that thickness to hold its own, and trust me im not gentle with it, and like you said it;s vary lightweight which is a plus even if it adds up when put as armor the weight would be evenly distributed so i won't feel it too bad and im also use to carrying lots of weight for long periods of time thanks to backing up&down mountains.
while I'm normally a firm believer in making my own toys, that includes armor as well. i thought i would share with you something the people of la will soon come to know and perhaps fear. i give you the newest tool in the LAPD'S war on crime, THE BODYGUARD.
its basically a stun gauntlet a hard ballistic plastic forearm cover that protects the wears arm while countering with a 300,000 vault tazer mounted near the wrist. why just stop the zombies bite. why not momentarily incapacitate for the finishing blow. after all stooping the bite is only half the battle. building batman one piece at a time...brought to you by Kevin Costner.