Armour Making  Class  (file number ArmourMaking1.doc) http://www.southtower.on.ca/armour/Requirements.html

Knowledge and skill sets that would be helpful before starting this course would include:
* historical basis for the use of armour
          --where it was made
          --who could afford it
          --when was it used.
          --how do we know what it looked like
          --museums which carry armour
          --reputable sources of information
*basic shop knowledge.
           --metal gauges
           --types of metal commonly used
           --spinnings, sheets, bar stock
           --shears, nibblers, jig saws, band saws
           --drills, drill presses, bits used on different metals
           --ball peen hammers, claw hammers, cross and straight peen hammers
           --anvils...sizes, hardies, edge characteristics
           --vices, post vices, bench vices
           --bench grinders, side grinders, sanding disks
           --rivets for leather, rivets for metal, standard types and sizes
           --pliers, vice grip pliers, needle nose pliers, tongs
           --gauge sets, measuring tools, markers for hot and cold metals
           --basic leather working skills, buckles
*fine arts knowledge
           --design considerations and layout techniques
           --armour gauges and weights for different uses, groups
           --historical designs, and principles
           --fluting and rolling requirments and why
           --decorative metalwork...inlay, onlay, guilding, repousse, fluting, plating
           --accessories  not limited to leather work.  


               



Metalworking Secrets to make Medieval Armour

     This 14 hour metal working class presumes the student has no experience in a metal shop environment, however, that being said, if the student comes in with the skill sets listed above, they will feel more at home.  With a bare minimum set of tools, and a strong emphasis on practical hands on experience, students will learn design of medieval armour, how and why it was effective, how medieval armour was made "back then" and how it is made in a modern armourer's workshop.  Two hour classes over seven days.  Instructor will provide homework packages for the theory portion of this course.  Instructor will require two hours prep over and above instruction time to manufacture blanks for students to shape into armour pieces.  
        There are no text books required for this class, but students should provide their own eye protection, hearing protection and work gloves. Work boots are not required.

day one........Introduction to armour use, including examining real armours and swords, with demonstrations on how effective armour is against swords, introduction to tools as used in an armourer's shop.  Shop should have the following, every 4 students will be responsible for a work bench,  armourer's anvil, wooden blocks (firewood baulks). Set of ball peen hammers, claw hammers, punches, drills, bits and rivets. Buffers and grinders, sandpaper and sandpaper blocks. Also scissors, sharpies, rulers and light cardboard to make templates as required. The function of each is explained. PPE (Personal Protective Equipment) is issued or requirements are explained...includes hearing protection, eye protection and gloves.  

Day two........ dishing as a method of creating a bowl shape.  Tools needed...block of firewood, ball peen hammer.  Students will all get a turn making a couple of standard elbow cops from pre made cut-outs of steel supplied by the instructor. Included will be a lecture on how to lay out patterns using scissors, sharpies, and light cardboard. (one hour instructor prep time required for this class)

Day three........planishing to surface finish the armour, Introduction to sanders and buffing machines.  Lecture portion of the course will be to observe the instructor demonstrate ancient sanding techniques, and contrast it to power machines. Modern sandpaper and sandpaper blocks will be used.  

Day four........rolling of edges. Riveting of steel.  Students will be given cut out armour pieces to finish roll with and without wire inclusion.  Topics covered include rolling, roping, finish-filing, and some embossing. Students will also learn about types of steel rivets used in armouring, how to upset them, and use them to join steel plates together. (one hour instructor prep time required for this class)

Day five......  Making chain mail.   Students will be taken through all the stages of making a piece of chain mail.  This will include winding the wire onto a mandrel, cutting the rings, closing half the rings, and knitting the closed rings together.  Some expansion and reduction techniques will be demonstrated in lecture format.  

Day six........Working with leather.  Making buckles, and attaching buckles to straps.  Students will learn how to layout and punch leather, (two types of punches) rivet with copper belt rivets, how to make and attach keepers, and how to work with different types of buckles.  Included is a half hour lecture on types of leathers, and their uses in armour manufacturing.  

Day seven.......Students will complete fully arming a mannequin or volunteer using chain mail, leather and  armour pieces they have made during the course. Lecture.........considerations involved in starting an armour making business, pitfalls, errors, and common mistakes.  Standards, who applies them, and why. Responsibilities of the armourer to make a safe product.