How to Forge Armor

Measure the dimensions of the person(s) who will be wearing the armor. Focus especially on the width of the chest, thighs, and, of course, the length of the arms, legs and torso.

Get a pattern for the type of armor you wish to forge. The site Armor Archive offers an extensive list of free patterns for helmets, breastplates, leg, arm armor and more. They simply expect that due credit will be given the pattern contributors.

Measure the pattern out to the dimensions of the person you measured before. Add an inch or two to all dimensions because you will loose some of it during the sinking process.

Sink the armor plates. Lay the piece out over a die, striking it with a long-edged sledge hammer. Strike until the desired depth of the piece/plate is achieved. If for whatever reason you cannot purchase a die, then you can use items like empty soda bottles.

Proceed to planishing the plates. This accentuates the shape of the armor and causes the metal to strengthen or harden. Place the armor plate on the flat face of your anvil. Hit every spot on the armor with the flat striking surface of the hammer until it has all the contours you want. If any spots on the armor require further attention, don't planish them as they will become to hard to amend.

Roll the edges of the armor. Place the edge against the edge of your anvil. Use a cross peen hammer to create a bend close to the top of the piece. Place the stake in a vise if it helps stabilize it. Flip over and make another. Fold the bends over a metal stake and then flatten the new roll on the anvil.