What am I really getting into, if I attempt to scratch build slat/bar armor with styrene stock?

It's way easier than soldering your own homemade PE, that's for certain. A jig would be a must for this project, to keep everything spaced correctly. It really shouldn't be too problematic. What's it for?

I want to do it for a Stryker, Warrior and D9R. I know that there are am sets out, but they cost a small fortune. I'm thinking it would be much cheaper and more fun to build it out of styrene. I have a mill, so should not have too much trouble making a jig.

Damn! I'm thinking of the possibilities here...
With a mill, you could produce a jig for every section of every vehicle you want on aluminum - cast it in resin, and sell them. I for one would pay for a jig to do slat in plastic rather than fooling with PE all the time.

Great idea! I'll keep that in mind. I'm not sure how long it will take me to get enough money together for the resin part of the process.