Using Cords To Make Soda Tab Armor

(click on pictures for a larger view)
Using cords to link the soda tabs is not only more cost effective, it is less preparation than working with metal rings. However, what you gain in speed and cost, you will lose in flexibility and realism.

Materials
First, it is good to have a pair of pliers handy in case you need to pinch down any rough edges that you may encounter with the soda tabs. Slip joint pliers , or needle nose pliers , or anything else that will still do the job, would be ideal.
Second, you will need an attachment method for linking the soda tabs. A type of cord, heavy weight fishing line, rope, or string should do the trick. Silver cord or heavy weight fishing line would be my preferred methods. The silver cord resembles much like a metal ring, and the fishing line isn't noticeable. The silver cord is what I used to demonstrate the instructions below. Silver Cord can be found at a craft store, and fishing line can be found at a Sporting Goods Store.
Using cords, strings, etc. to secure the soda tabs will make the armor more restrictive in your movements. Stay away from elastic type cords to make up for the flexibility loss, it will result in the armor looking messy and unrealistic. Much like scale mail armor, soda tab armor should hang loose, so make sure you add enough tabs to move comfortably within the armor.
Third, you will need scissors for cutting the cord, fishing line, etc.
Last, but not least, make sure you have a pattern and plenty of soda tabs for your project.

Getting Started (Remember to click on pictures to enlarge, for easy to follow instructions.)
Now that you have everything you need, lets get started!

For Step 1, thread two soda tabs face up . When tying off the tabs, they should be folded face to face as in Step 2. This is your start off point so make sure you tie several knots making sure it is secure. Unfold tab and make sure your knot is secure on the back of the tabs. Do not tie the tabs together too tight, causing the tabs to overlap. They should be able to sit side by side as in Step 3. Take the long end of the cord and thread through the top hole of the right soda tab for Step 4. Thread your next soda tab through the bottom hole from back to front and place over soda tab like the picture here in Step 5 . For Step 6, thread your next soda tab through the bottom hole from front to back .
Thread the cord through the bottom top hole of soda tab securing all four tabs, for Step 7.
Turn your tabs over with the backs facing up and begin tying a loose knot, as in the example pictures of Step 8 , and Step 9 . After securing a loose knot, your tabs should look like the picture in Step 10, and that is it! It is that easy!
All you have to do now is repeat what you've learned. Turn your tabs over and thread your cord through the top right hole of your tab, as in Step 4 , then rinse and repeat the process through steps 5-10. Keep repeating Steps 4-10 until you have long strips of attached tabs that look like this . On the back, your knots should look like a continuous pattern up the back of the soda tabs strips.
You can count how many tabs you need to match your pattern for the long strips. I often prefer to just make many pre-counted long strips while watching TV, or teaching Home-school. I attach the strips together later to make the necessary panel of the pattern that I am working on.

Attaching the Tab Strips
It is easier to work with the tab strips when the back is face up, like so . When attaching the tab strips together, thread and knot them the same as making the individual strips .
Your on your way! Turn your work over, front side up, and double check your panel portion for any errors .
After attaching the strips together to make one panel, it is easier to keep the panels separate until all the panels are finished. Then, attach the panels together according to the pattern, saving the top shoulder attachment for last.

Attaching New Cord
Nothing is more frustrating than when you run out of project materials. So always keep a current wrapper, box, or receipt handy to be able to make a positive match when going on a store run, or making more than one of the same project.
Once you have your new cord, you can simply tie it to your old one, securing a knot, and cut off the excess to make a continuous flow of cord. Or, you can turn your tabs over and tie off and secure the position of the tabs where you are currently at, and cut off the excess . Then, simply tie on the new cord at the next step .

Top Shoulder Attachment
Have your shoulder panel tops lined up touching top to top . The tops of each panel should be ready to connect. Overlap the top of the soda tabs of the shoulder panels, and link them with the cord. Make sure if one tab is overlapping on top, that the rest overlap on top as well. For Example; as seen here in the picture , I have the right soda tabs overlapping on top of the left ones. Turn your work over and begin threading the tabs by knotting them along the shoulder seam going sideways .

Tying End Tabs
When you are finished attaching the panels, tie off any 'end' tabs so they are not free to move around. As in the pictures, End Tabs: Step 1 and Step 2 . The end tabs would be located on the back panel, around the arm hole, shoulders, and neckline. Tie along the edges up the side of the tabs along the panel, or across the tops of tab holes. This may seem like a lot of extra work, but it makes the armor look less messy when they are secured and not left to wiggle around.

Try It On!
By following the pattern carefully you should have a complete soda tab vest.
To wear the armor, lace the back panels loosely, like a shoelace, through the tab holes with left-over cord. Once you have the vest on, you will need help to tighten and tie the armor, since the lace is located in the back. Make sure it is someone you trust to tighten the lace and tie a loose bow, and be there later to get you out again. Ha!
Whoohoo! We are finished!