Things You'll Need
Instructions
Measure around your chest at the widest point. Divide the number by 8 for eight rows of armor plates. This will give you the length you need to cut your metal banding, about 3 to 5 inches. Alternatively, choose cut longer strips for the center two rows on the front and the back and shorter strips for the outside rows.
Cut and clean the banding. Cut the banding to a manageable length of 3 to 4 feet. Clean the banding with an emery cloth or sandpaper.
Cut the banding into small strips with the tin snips using the lengths you measured. Create one strip the proper length, then use it as a template for cutting the remaining plates. Armor will require hundreds of strips.
Punch three holes evenly on the side of each plate using a 5/32 bit on the metal punch set to the narrowest setting. Punch holes along the top for the eight topmost plates, then punch holes in only one side of about 50 plates for the side rows of armor that will connect the front and back of the armor together.
Bend the plates so that they are smooth and rounded by rolling a rubber mallet or a heavy bowling ball over them as they rest on the round object. You can also curve plates on a bullnose kitchen counter or a round bannister.
Assemble the rows of armor by connecting them with maille rings for battle-worthy armor or leather strips for decorative wear. Create two rows of eight strips punched on only one side for the upper chest and two more for the upper back. Attach them together in the center.
Make two sections that are eight plates tall and four columns wide for the rest of the armor that covers the remainder of the torso. Connect the shoulders with maille or leather. Connect the sections together with SCA regulation leather strips that create a belt around the armor.