Medieval armour is a symbol of craftsmanship, history, and tradition. Whether you're a historical reenactor, cosplayer, or blacksmithing enthusiast, learning how to make medieval armour can be a rewarding journey. This in-depth guide will walk you through everything you need to know—from materials and tools to forging techniques—so you can start crafting your own authentic armour.
Table of Contents
What Is Medieval Armour?
Medieval armour was a critical part of a knight's protection during the Middle Ages, evolving from simple chainmail to full plate armour. It was designed to shield warriors in combat while allowing a reasonable range of motion.
Understanding the components—like the helmet (helm), breastplate, greaves, gauntlets, and chainmail—is essential before you begin crafting.
Types of Medieval Armour
There are several distinct types of armour you can make:
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Chainmail (Maille) – Interlinked metal rings. Flexible and time-consuming to create.
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Scale Armour – Small metal plates sewn or riveted onto leather or fabric.
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Brigandine – A cloth or leather jacket with metal plates riveted inside.
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Plate Armour – Large shaped steel plates for maximum protection.
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Leather Armour – Boiled or hardened leather used for lighter protection.
Each style has its own build process, materials, and historical significance.
Essential Tools and Materials
Before diving into how to make medieval armour, gather these tools:
Tools:
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Anvil
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Ball peen hammer
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Tongs
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Rivet gun
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Leatherworking tools (if using leather)
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Tin snips or metal shears
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Drill press or hand drill
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Files and sandpaper
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Forge or propane torch (optional)
Materials:
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Mild steel or stainless steel (16-18 gauge for plate armour)
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Aluminum (lightweight alternative for cosplay)
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Leather (for strapping or brigandine)
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Rivets or solid brass pins
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Buckles and straps
Pro Tip: Use mild steel for authentic weight and durability, but aluminum is easier for beginners.
How to Make Medieval Armour: Step-by-Step Guide
Let’s break down the process of making a simple piece of plate armour—a vambrace (forearm guard).
Step 1: Design and Pattern
Start by tracing your arm on cardboard or using a pattern book. You can also find free templates online for different armour pieces.
Step 2: Cutting the Metal
Transfer your pattern to the sheet metal and cut it using tin snips. Be sure to wear gloves and goggles.
Step 3: Shaping the Armour
Heat the metal with a propane torch if needed, then use your anvil and hammer to shape the piece into a curve that fits your arm.
Step 4: Smoothing and Polishing
File down any rough edges and sand the metal to a smooth finish. You can polish it to a mirror shine for authenticity.
Step 5: Drilling and Riveting
Drill holes where your straps will go. Use rivets to attach buckles and leather straps, ensuring a snug but comfortable fit.
Step 6: Test and Adjust
Wear the armour and check for mobility. Make adjustments by reshaping or refining the fit.
Repeat the process for other armour parts—shoulders (pauldrons), chest (cuirass), legs (greaves), etc.
Safety Tips
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Always wear eye protection and heat-resistant gloves.
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Work in a well-ventilated area.
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Keep a first aid kit nearby.
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Start with small pieces before attempting full suits.
Resources for Learning and Supplies
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Books:
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Techniques of Medieval Armour Reproduction by Brian R. Price
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The Armourer’s Workshop by Thom Richardson
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Online Communities:
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MyArmoury.com
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Reddit: r/blacksmith
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Supply Stores:
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ArmourArchive.org
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Jantz Supply
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Tandy Leather (for leather components)
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FAQs About Making Armour
Q: Is making medieval armour expensive?
A: It can be, depending on materials and tools. However, beginners can start with basic hand tools and scrap metal.
Q: Can I make armour without a forge?
A: Yes! Cold shaping with a hammer and anvil is very doable for beginners.
Q: How long does it take to make a full suit?
A: Anywhere from 50 to 300 hours depending on detail, experience, and type of armour.