PATTERNING TRICKS
The patterns are the foundation of the armour making process. At Blankenshield
we work almost as much with the pattern for each project as with the metal.
Armour will not stretch or move to fit so it must be designed to fit in
the first place. To be safe when working out unfamiliar designs, lay out
the plate you think you need then add an inch or so all around. Then sink
and planish it. Then before rolling the edges match the plate to those on
each side and the person being fitted and trim to suit. Then roll all edges
before assembling. When Blankenshield began patterning we blew up photographs
of armour to life size and took measurements from them. That helped some
but there are traps. We frequently resort to assembling paper patterns like
models to resolve some design issues but there is a factor we call DRAFT
AND DRAW!. Each time depth is added to a plate the edges are affected. Some
misinformed blacksmith types seem to think that the steel thins appreciably
during the COLD sinking process but this is not true. The steel acts rather
fluid like and pulls in at the edges to varying degrees instead. This alters
the shape and size of the finished piece according to two factors. One,
the depth. And two, the distance from the maximum penetration to the edge.
As a result of this mathematical force the stresses build up especially
bad in the inside curves like the armpit of a breastplate. The resistance
of the metal to flowing is worse over the longer distances to either side
of the armpit so the armpit cutout section will draw deeper than the metal
to either side. So when you lay out inside curves make them shallower than
you expect to need and the depth will draw the inside curves deeper. Always
allow three quarters of an inch all around for rolling of the edge. Many
configurations on the arms and legs especially are sections of a cone and
stacked like cones. So pieces that look straight edged on the armour actually
are curved pieces. Edges that are straight before pounding depth will turn
concave after depth has drawn in the edges. All plates get smaller according
to the depth pounded into them. When a difficult configuration is confronted
sometimes it helps to change the design to several smaller pieces rather
than one larger one. As a general principle there are one or more small
metal strips called interstaciary lames between all major components. Elbows
(couters) and knees (polyns) for example each have a piece with depth over
the joint with tubular components (cannons) over and under them. The pieces
with depth and the tubular cannons are connected by the thin interstaciary
lames. Some times what is called a stand off lame is required for an articulation
to work right. For example some neck lames on closed helms will not pivot
enough to clear the way to move the head forward and down so that lame is
divided into a stand off lame that pivots a little bit and provides the
space for the real neck lame to pivot on. In all patterning consideration
must be made for sufficient overlap of components in all positions. Most
designers make the mistake of designing limbs from the straight position
intending them to be bent. At Blankenshield we design the joints in a bent
position intending them to be straightened. There is a big difference. Early
in the middle ages they started battering then rolling steel into sheets.
These sheets were delivered from manufacturing centers in pieces the size
of a mule pack and strips called whisps. We can get it in sheets ten feet
long now days. The flat metal is first cut using a paper pattern and a crayon
to mark it on the metal. Artists pastels work well on any metal and even
show after heat like welding operations. |
