This post is all about making armour…
As many of you may know, I love sallets. I love the lines and shape of them and have in time modelled my kit and impression around the need to wear them. Anyway, my current sallet has been in service for about 15 or 17 years. I love that helm but it was getting time to replace it, as all things will wear out eventually.
I intended to replace it with basically the same thing. There would be a few small changes to things I got wrong all those years ago. I have been intending to get started on this for a long time, but always had other projects on the go. I have also been looking at some of the posts on Armour Archive about a raising technique that makes things very fast and I wanted to try this new method out.
Basically you make up the helm in flat sheet with only two dimensional bends. You weld it all up and then sand back the welds flush. Then, under heat, you work the form down to the desired shape. The technique was developed by Robert Macpherson, whose work is fantastic and I wish I had 1/10 of his eye and talent. The raising involves compressing the metal and hammering the form from the outside rather than working the form from the inside as is common with a lot of modern armouring. I did a test run on a shield boss and it worked a treat. So I drafted up a pattern based on the old helm and off to the workshop!
Here is the pattern mock up next to the old helm.
I drafted the pattern over the old helm. This ended up being a big mistake. This technique requires you get the pattern spot on, as I will explain soon…
Cutting out the plates.
From here it is a straight forward job of bending the plates and welding it all together. The top portion of the helm is in 2.5mm mild and the bottom plates are 2mm.
Top of the helm welded up.
The front of the helm. Top welds have been sanded back.
Helm all welded up. I should have done the bottom plate in one piece. The weld there would cause problems latter on…
After this I sanded back the welds on the outside. I am supposed to do the same for the inside welds but these were relatively flush anyway (the bonus of doing with gas welding) so I did not spend too much time doing this.
The next step is to light up the torch and start hammering.