How to make plate mail

A noble pursuit! Making plate mail, also known as plate armor, is a challenging and rewarding project that requires some metalworking skills, patience, and dedication. Here's a step-by-step guide to help you get started:

Materials needed:

• Metal sheets (copper, steel, or aluminum) for the plates
• Wire (copper, steel, or aluminum) for the rivets
• Rivet sets (optional)
• Leather or fabric for the backing
• Measuring tape
• Pliers
• Drill press or hand drill
• Safety goggles
• Workbench or anvil

Design and planning:

1. Determine the size and shape of your plate mail. You can use a pattern or design your own. Consider the size of the wearer, the type of armor, and the level of protection needed.
2. Decide on the number of plates and their arrangement. Typically, plate mail consists of overlapping plates that cover the torso, arms, and legs.
3. Plan the rivet pattern. You'll need to space the rivets evenly to ensure the plates stay in place.

Cutting and shaping the plates:

1. Cut the metal sheets into the desired shapes using a saw or a shear.
2. Use a file or a grinder to smooth out the edges and remove any burrs.
3. Use a drill press or hand drill to create holes for the rivets.

Riveting the plates:

1. Cut the wire into lengths for the rivets.
2. Use a rivet set or a hammer and anvil to shape the wire into rivets.
3. Place a rivet through the hole in each plate and bend it into shape.
4. Use a hammer and anvil to flatten the rivet head and secure it in place.

Assembling the plate mail:

1. Place the plates on a workbench or anvil, overlapping them as desired.
2. Use a rivet to attach each plate to the next, working your way around the armor.
3. Use a hammer and anvil to secure the rivets in place.
4. Repeat the process for each plate, working your way around the armor.

Adding a backing:

1. Cut a piece of leather or fabric to fit the back of the plate mail.
2. Glue or sew the backing in place, making sure it's secure and even.

Finishing touches:

1. Use a file or a grinder to smooth out any rough edges or burrs.
2. Apply a finish, such as a coat of varnish or a rust inhibitor, to protect the metal.
3. Add any additional details, such as a helmet or gauntlets.

Tips and variations:

• Use a variety of metals, such as copper, steel, or aluminum, to create a unique look.
• Add decorative elements, such as engravings or etchings, to the plates.
• Use different shapes and sizes of plates to create a more complex design.
• Experiment with different rivet patterns and arrangements to create a unique look.

Remember to always follow safety guidelines when working with metal and power tools. With patience and practice, you can create a beautiful and functional piece of plate mail.