I'm lucky that at work we have some stuff that is used for sport equipement that I used to put in my plate carriers. We got them from a company called kristoFOAM located in Ontario and it came in black. It's firm but still soft enough to wear comfortablely. I can't remember the product name but I'll try and find it if you need.
Wey ferro's solution looks great if you want to get some easierly. The real soft armour is about 0.210" thick IIRC and a 0.250" pad works great. Makes your plate carrier look better with the added thickness. I also use a 0.750" pad to cut the shape of the SAPI plates.
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bruce: Team Bad Karma-(BK-05)
: Special Battalion East-(SBE-01)
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