AR500 Armor® Body Armor vs 12 Gauge Penetrator, Slug, & Buckshot Loads!

AR500 Armor® Body Armor vs. 12 Gauge Buckshot, Slug, and Penetrator Loads

Test Date: September 22, 2020

Testers: Iraqveteran8888 (Eric & Ray)

Armor Tested: AR500 Armor® Level III Steel Body Armor

The team at Iraqveteran8888 put AR500 Armor® Level III body armor through an intense real-world shotgun test. Using a ballistic gel torso nicknamed “Joe Fit” — complete with a ballistic gel head — they simulated defensive and law enforcement scenarios, firing a range of shotgun loads including hunting shells, defensive buckshot, and hard-hitting slugs.

The goal: evaluate both the penetration resistance and the anti-spall coating effectiveness when hit with various 12-gauge loads at close range.

Why Test Shotgun Loads?

While rifle threats are often the focus of armor testing, shotguns remain one of the most common close-range firearms in defensive and tactical situations. A police officer entering a building, or a homeowner facing an intruder, could encounter buckshot or slugs at extremely close distances.

These tests simulate that high-risk environment, where armor performance can mean the difference between life and death.

Buckshot Testing

Federal 2¾” Double-Ought Buck

• Specs: 9 pellets, 1,325 fps
• Range: ~7 yards
• Results: The armor absorbed all impacts in a tight cluster with no penetration and no spall reaching the head. Minimal backface deformation was noted.

Federal 3” Magnum Double-Ought Buck

• Specs: 15 pellets, 1,210 fps
• Range: ~7 yards
• Results: Wider pattern than the 2¾” load, but all pellets stopped by the plate. Even edge strikes did not cause spalling to reach the gel head.

Triple-Ought Buck (.36 caliber pellets)

• Specs: 8 pellets, 1,325 fps
• Results: All projectiles stopped, with the anti-spall coating capturing fragments. After multiple hits in the same area, the plate showed raised coating but remained intact.

Slug Testing

Federal TruBall Slug (1 oz)

• Velocity: ~1,600 fps
• Results: Significant energy transfer but no penetration. The plate’s coating prevented spall from reaching the gel head.

Federal Rifled Slug (1¼ oz)

• Velocity: ~1,520 fps
• Results: Direct upper-plate hit caused slight coating separation at the edge but no spall penetration through the carrier. Demonstrated the coating’s effectiveness even under concentrated impact.

Brenneke Special Forces Barrier Penetrator Slug (1⅜ oz)

• Velocity: ~1,630 fps
• Results: Delivered extreme impact, denting the plate and slightly damaging the hat brim on the gel head, but no facial damage. The plate remained functional despite heavy abuse.

Aftermath: Ballistic Gel Without Armor

To demonstrate the importance of armor, the team removed the plate and fired slugs directly into the gel torso.

Results were dramatic — deep penetration of 14–15 inches, fragmentation of lead, and significant destruction to the gel torso. The comparison illustrated the life-saving difference armor provides.

Key Takeaways

• No 12-gauge buckshot or slug in this test penetrated AR500 Armor® Level III plates.
• Anti-spall coating effectively captured fragments and prevented dangerous ricochet to the head and face.
• Multiple, repeated hits in the same spot eventually degraded coating, but the armor maintained structural integrity.
• Without armor, shotgun slugs cause catastrophic injury in ballistic gel.

Conclusion: AR500 Armor® Level III steel plates provide reliable, repeatable protection against common 12-gauge defensive and hunting loads, making them a viable option for close-quarters defense scenarios.