How to make scale mail shirt

A scale mail shirt! A fantastic project for any medieval enthusiast or cosplayer. Here's a step-by-step guide to help you create a scale mail shirt:

Materials needed:

• Aluminum or steel scales (you can buy them online or make your own using metal sheets and a jigsaw)
• Leather or fabric for the shirt body and straps
• Thread or wire for sewing and attaching scales
• Measuring tape or string
• Pliers or a scale mail punch
• Hammer or mallet
• Safety glasses and gloves (optional)

Step 1: Measure and Plan Your Shirt

• Measure your body to determine the size of your shirt. Take note of your chest, waist, and arm length.
• Decide on the style of your shirt: medieval, fantasy, or historical. This will influence the design and shape of your shirt.
• Plan the layout of your scales. You can use a grid pattern or a more random arrangement.

Step 2: Cut Out the Shirt Body and Straps

• Cut out the shirt body from leather or fabric, using your measurements as a guide. Leave a small margin around the edges.
• Cut out straps from leather or fabric, which will connect the scales to the shirt body.

Step 3: Cut Out the Scales

• Cut out the aluminum or steel scales using a jigsaw or a metal cutting saw. You can also use a scale mail punch to create the scales.
• Cut the scales to the desired shape and size. You can use a template or draw the shape freehand.

Step 4: Assemble the Scales

• Use thread or wire to attach the scales to each other, forming a chain-like structure. You can use a simple over-under pattern or a more complex design.
• Use pliers or a scale mail punch to shape and bend the scales into place.

Step 5: Attach the Scales to the Shirt Body

• Use thread or wire to attach the scales to the shirt body, starting from the bottom and working your way up. Make sure to space the scales evenly and securely.
• Use a hammer or mallet to gently tap the scales into place, if needed.

Step 6: Attach the Straps

• Attach the straps to the shirt body, using thread or wire. Make sure they are securely attached and evenly spaced.
• Adjust the straps to fit comfortably around your body.

Step 7: Add Any Additional Details

• Add any additional details, such as a clasp or a brooch, to the shirt.
• You can also add decorative elements, such as embroidery or metalwork, to the shirt.

Step 8: Finish and Wear

• Finish the shirt by adding any final touches, such as a coat of varnish or a layer of fabric to protect the scales.
• Wear your scale mail shirt with pride!

Tips and Variations:

• Use a variety of scale shapes and sizes to create a unique and interesting design.
• Experiment with different materials, such as copper or bronze, for a more rustic or aged look.
• Add padding or a lining to the shirt for added comfort and protection.
• Create a more elaborate design by adding additional features, such as a hood or a gorget.

Remember to always prioritize safety when working with metal and sharp objects. Wear safety glasses and gloves to protect yourself from injury. Happy crafting!