Making armor

For Historical European Fighting Arts, Weaponry, & Armor

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Will Adamson
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Location: Abingdon, VA

Making armor

Postby Will Adamson » Sun Sep 24, 2006 4:16 pm

Who is the resident armor guru?

I was wondering about getting into making clothing and armor so that I could make things more to my liking and not have to put up with dealing with a retailer. I'm not looking to start out with a full set of tilting harness or anything. Just maybe some brigandine and components of plate.

Something tells me the Virginia Beach Armored Think Tank (someone else's term, not sure who it was) would have the answers.

Any thoughts or advice on how to get started?

Edit: I just searched it out, and the Think Tank line was from Stacy Clifford. Must give credit where credit is due.
"Do you know how to use that thing?"
"Yes, pointy end goes in the man."
Diego de la Vega and Alejandro Murrieta from The Mask of Zorro.

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Brian Hunt
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Postby Brian Hunt » Mon Sep 25, 2006 2:49 am

Hi Will,

You asked a mouthfull.

You need several things to get started with armour.

You need a dishing or sinking stump. This can be as simple as a depression shaped like a bowl carved in a stump or as nice as the bottom of a large oxygen bottle.

You will need a sinking hammer and a planishing hammer. A sinking hammer is a hammer with a domed surface that has been mirror polished, you can reshape a single jack or use the ball end of a ball pien but this leaves lumpier results. For a planishing hammer you can use a mirror polished hammer face, an autobody hammer works but is light, a standard claw hammer, etc.

You will need a way to cut your steel. Hammer and chisel (slow but sure), Jigsaw with metal cutting blade (nosy), a hand held power shear, or my favorite a bench mounted throatless shear ( a decent one may be found at harbor freight).

You will need a planishing stake this make be a mirror polished dumbell from walmart, A 2 and a half inch trailer hitch welded to a stake and the flat spot ground smooth and round, a large mill ball welded to a stake, a shot put welded to a stake, or you can also use a large four inch fence ball post from your local fencing supply. A planishing stake should be kept mirror polished this helps you later on in your work.

I would reccomend a workbench of some type ( a decent heavy wood bench dedicated to a stake plate and to hold your other work tools woudl be nice).

I would reccomend a bench vise.

As for an anvil, you really don't need one for armour. You just need a heavy metal surface to set rivets on. You could do this on the small anvil face of your bench vise, or get a convienant hunk of steel, a piece of rail road track, a small length of i-beam, use your imagination and find it cheap from the scrap yard.

You will need a way to polish your armour (if this is your goal) or you can leave it rough from the hammer. Polishing involves the use of a buffer and a way to sand your armour. It may be as simple as an expanding drum sander on your buffing motor (an inexpensive one may be obtained at Harbor freight, I use one from Grizzly), to a high end belt grinder. Buffing starts with a sisal buff ( a sisal rope buff would be really nice and aggressive) and black rouge, followed by cotton buffs with a white or green compound.

You will need a way to make holes, a drill and bits works well, but I prefer a punch (faster and more accurate). If you use a drill be sure to use a center punch to keep your bit from wandering.

A good book on how to make 14th century armour is sold by Brian Price and is often abreviated as TOMAR. Also here is a ok .pdf on how to get started in armour. http://www.brighthelm.org/armour/

You will also need patterns. See http://www.thearmourarchive.org for patterns and nice information and also http://www.arador.com for other articles on making armour.

Clothing is a whole other can of worms. There are several good patterns out there, but a lot of them you will have to create from scratch. Use proper cloth such as cotton, Linen and wool.

If you are thinking of making mail, that is another topic.

The main trick is to get in, make some mistakes and learn from them (much like learning to fight with a sword), then practice, practice, practice.

When you really start to under stand the steel you may wish to get a forge and start raising instead of sinking your armour. This is how they made helmets from one sheet of steel instead of the modern method of welding them from 2 to 3 pieces.

hope this helps, and good luck.

Brian Hunt
GFS

P.S. look at as many pictures as you can of the orginal armour from musuems, private collections, etc. This will help your eye start to learn the proper lines for armour.
Tuus matar hamsterius est, et tuus pater buca sabucorum fundor!

http://www.paulushectormair.com
http://www.emerytelcom.net/users/blhunt/sales.htm

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Will Adamson
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Postby Will Adamson » Mon Sep 25, 2006 6:25 am

Thanks Brian.

If I get started in this I'm sure I'll be doing a few shield umbos and bucklers (I'm guessing they would be the most simple) before I tackle some sort of helmet.

What is the time commitment like? Let's say I'm working on the beforementioned buckler, have all the necessary tools, done my reading, but don't have much experience. A couple of hours? All day?

I'm really not sure I want to delve into this, just thought I'd test the waters.
"Do you know how to use that thing?"

"Yes, pointy end goes in the man."

Diego de la Vega and Alejandro Murrieta from The Mask of Zorro.

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Brian Hunt
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Postby Brian Hunt » Mon Sep 25, 2006 7:08 am

You will have a learning curve. Your first pieces will take a lot longer than later pieces will. For instance, lets take your buckler or umbo example. These have to be dished or raised really deep, this takes more time than say the shallower dish on a pair of spaulders. It will also depend upon the thickeness of the steel you are using, an 18 gage umbo will take less time to form than a 14 gage umbo. I held a workshop at my home earlier this year where I taught beginners how to make spaulders. We spent all day on them and most of the participants finished both of their spaulders, while a few completed only one and most of the second one. I recently started a 14 gage bascinet, so far I have about 15 hours into it and I only have the main body of the helmet shaped welded and rough polished. I still need to make the klapp visor, the hinge, add verevelles then sew up the padded enterior/aventail and add a mail aventail.

hope this answer helps, like all things it depends.

Brian Hunt
GFS
Tuus matar hamsterius est, et tuus pater buca sabucorum fundor!



http://www.paulushectormair.com

http://www.emerytelcom.net/users/blhunt/sales.htm

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Will Adamson
Posts: 378
Joined: Thu Dec 29, 2005 11:01 pm
Location: Abingdon, VA

Postby Will Adamson » Mon Sep 25, 2006 8:31 am

That's more than I was hoping for, thanks again!

I just spent some time on the links you provided. The Arador site looks fantastic!
"Do you know how to use that thing?"

"Yes, pointy end goes in the man."

Diego de la Vega and Alejandro Murrieta from The Mask of Zorro.

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Brian Hunt
Posts: 969
Joined: Thu Jan 23, 2003 2:03 am
Location: Price, Utah
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Postby Brian Hunt » Tue Sep 26, 2006 2:36 am

Arador had a fantastic forum but some destructive so and so decided to hack their forum and erased their entire database of excellent information on armour. They are opening a new website with a new forum that should be worth checking out for those interested. The link is on their website when you try to go to the forums area.

Brian Hunt
GFS
Tuus matar hamsterius est, et tuus pater buca sabucorum fundor!



http://www.paulushectormair.com

http://www.emerytelcom.net/users/blhunt/sales.htm

Cory Watkins
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Joined: Fri Dec 09, 2005 10:45 pm

Postby Cory Watkins » Tue Sep 26, 2006 11:12 am

i miss the arador forum, I was becoming a fairly regular poster right as they were hacked.......i want said hackers ip address, i assur i have enough computer sitting around to do something realy pleasent to him....

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Will Adamson
Posts: 378
Joined: Thu Dec 29, 2005 11:01 pm
Location: Abingdon, VA

Postby Will Adamson » Tue Sep 26, 2006 12:02 pm

It wasn't some dude in Turkey was it?

When this forum went down I had to spend more of my time over at bikeforum.
"Do you know how to use that thing?"

"Yes, pointy end goes in the man."

Diego de la Vega and Alejandro Murrieta from The Mask of Zorro.


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