How to make scale mail scales

A great question for all you fantasy enthusiasts and DIY enthusiasts out there!

Scale mail, also known as lamellar armor, is a type of armor that consists of small, overlapping scales or plates made of metal, leather, or other materials. To make scale mail scales, you'll need some basic crafting skills and materials. Here's a step-by-step guide to help you get started:

Materials needed:

• Metal or leather sheets (depending on the type of scale mail you want to make)
• Wire (copper, aluminum, or steel)
• Pliers
• Hammer
• Anvil
• Sandpaper or a file
• A template or pattern (optional)

Instructions:

Method 1: Metal Scale Mail

1. Cut out small rectangles or squares from the metal sheet. The size will depend on the scale mail pattern you want to create. For a simple scale mail, you can start with rectangles that are about 1-2 inches (2.5-5 cm) long and 0.5-1 inch (1.3-2.5 cm) wide.
2. Use wire to create the scale's edges. Cut a piece of wire and bend it into a U-shape. Place the wire around the edge of the metal rectangle, overlapping the ends by about 1/4 inch (6 mm). Use pliers to secure the wire in place.
3. Repeat step 2 for each edge of the metal rectangle, creating a U-shaped wire border around the entire scale.
4. Use a hammer and anvil to shape the metal scale into a curved or wavy shape, if desired. This will help the scales fit together more smoothly.
5. Sand or file the edges of the scale to smooth out any rough spots.
6. Repeat the process to create multiple scales.

Method 2: Leather Scale Mail

1. Cut out small rectangles or squares from the leather sheet. The size will depend on the scale mail pattern you want to create. For a simple scale mail, you can start with rectangles that are about 1-2 inches (2.5-5 cm) long and 0.5-1 inch (1.3-2.5 cm) wide.
2. Use a leather punch or a sharp object to create a hole at the top of each leather rectangle, about 1/4 inch (6 mm) from the top edge.
3. Thread a piece of wire through the hole and use pliers to shape the wire into a U-shape. Place the wire around the edge of the leather rectangle, overlapping the ends by about 1/4 inch (6 mm). Use pliers to secure the wire in place.
4. Repeat step 3 for each edge of the leather rectangle, creating a U-shaped wire border around the entire scale.
5. Use a hammer and anvil to shape the leather scale into a curved or wavy shape, if desired. This will help the scales fit together more smoothly.
6. Sand or file the edges of the scale to smooth out any rough spots.
7. Repeat the process to create multiple scales.

Assembling the Scale Mail

1. Once you have multiple scales, you can start assembling the scale mail. You can use wire to connect the scales together, overlapping them slightly to create a continuous armor piece.
2. You can also use a template or pattern to help you create a specific scale mail design or pattern.
3. To add additional protection, you can layer multiple scales together or add additional materials, such as fabric or padding, between the scales.

Tips and Variations:

• You can use different materials, such as plastic or 3D-printed scales, to create a more modern or futuristic scale mail design.
• You can add decorative elements, such as rivets, studs, or engravings, to the scales for a more ornate look.
• You can also create scale mail with different shapes, such as triangles or hexagons, for a more unique design.
• If you're making scale mail for cosplay or costume purposes, you may want to consider using a lighter material, such as foam or cardboard, to create the scales.

Remember to always follow safety guidelines and precautions when working with sharp objects, hot tools, or other materials that may pose a risk to your safety. Happy crafting!