any interest in a few armouring instructables?

I was planing on making an instructable for a helmet the next time i built one, but I've got a few projects to do before I get to it, so I'm not sure when I'll actually get around to it.

In the meantime, here's a quick how to for a great helm. they are actually fairly easy and are one of the more recommended beginner projects.

to start with here is a good pattern to start from. You'll most likely have to tweak it a bit to make it fit your head, but that's easy.
http://www.armourarchive.org/patterns/greathelm_sinric/

tool wise you'll need a jigsaw or something to cut metal,
a drill to make holes,
a file for cleaning up the edges,
a couple hammers, you could make due with just one ball peen but I'd recommend some kind of dishing hammer, a smaller riveting hammer and a rubber mallet.
a piece of pipe or something similar to curve the plates around, I've seen people just do it by hand over their thighs before, but that's a bit more difficult.
some kind of chunk of metal to rivet onto,
6D nails for rivets, and small bolts for temporary rivets.
side cutters or something to cut the nails down to rivet size.
scissors and a sharpy for patterning and marking on metal.
and something with a solid corner you can flare the edges of the cap down on. alternately you can just cut tabs and bend them down, not as nice looking, but just as historical and easier.

start by making up a mock up or 6 until you have the pattern scaled to fit your head the way you want. I recommend using bristol board or old cereal boxes or something like that. make sure to factor in whatever padding you'll have under it.

once you have that start by cutting out the plates for the upper hoop. bend them into shape, drill your rivet holes and then bolt it together. form there tweak it until it's good and symmetrical.

next pattern the top plate out by simply tracing out the top of the helmet onto some more bristol board or whatnot. add 1/2" to 3/4" all around. if you're going the tabs rout cut small wedges around that extra border to make your tabs, check that the paper template fits right then transfer it over to steel and cut it out. dish the top if you're doing that now(not necessary bit ti looks nice) then fold over your tabs and rivet it into place. If you decided to flare the edge down you'll need to do it pretty much the same way i flare out the rim in my dishing instructable, the difference being that you'll be doing it in the opposite direction, thereby compressing the metal. this means that it'll take a whole bunch of small passes, but take your time and it should work fine. make sure to do frequent fittings, and once your happy, drill your holes and bolt it onto the top of the helm.

Next check that your paper patterns for the bottom hoop still work with the metal top(they don't always) make any changes you need to, then cut them out of your metal. since there most likely wont be any complex forming here you can mark and drill whatever pattern of breaths you like in the face plates, then bend the plates into shape, drill your holes and bolt the bottom hoop together. you will probably have to flare the top of the hoop in a little to make it sit right where it meets the upper hoop. once it fits right bolt the whole thing together and give it a good once over, make sure your happy with everything.
Are you happy? good.
The brass work is optional, but if your doing it now is the time. I;d pattern it out with a few layers of masking tape, a sharpy and a exacto knife. once you like how it looks peel off the tape, transfer it to your trim, cut it out, file off any burrs and whatnot, and bolt it in place. everything still looks good? good.

Now, take the whole thing apart, do whatever finishing you plan for the helmet (paint, polish, russet, sand, whatever). once that's done it is finally time to rivet it all together. start by bolting the top hoop mostly together. now pull out a bolt and replace it with a rivet, this makes sure nothing warps or gets bent out of place. next do the same with the top cap. once thats in place put the bottom hoop together, then lastly add the bottom hoop to the top.

when your setting your rivets it'll be easiest to put the nail head (or rivet cap if you buy actual rivets, i never do though) on the outside, lay the helmet against your riveting surface and peen the rivet inside the helmet. it's a little awkward at first, but trust me, it's much easier than trying to brace the head of the rivet from inside the helmet.

I hope that helps until i get around to doing a proper instructable. if you have any more questions feel free to ask em, also the forums at www.armourarchive.org are full of goodness. just read the stickies first and don't be rude.

If you do make yourself a greathelm I;d love to see pics of it finished.
wow, thats a long comment.

http://www.instructables.com/id/How-to-peen-a-rivet/
In this instructable i used a roofing nail, but just because it;s what i had at hand. Roofing nails are good for riveting in leather straps and the like, but for metal to metal just get some 6D nails from the hardware store.a pound will cost you a couple dollars tops and last for a long time. get the shortest ones they carry since you'll be cutting most of the point off anyways.

you shouldn't need a blowtorch for making a great helm. none of the shapes are complex enough to need heat, and if they were a regular blowtorch doesn't heat up a large enough area anyways. I've tried.

more or less. you kind of have to work your way around the edges at first. it's hard to describe. I should see if i can add a video to that instructable. In any case I'd really recommend practicing riveting some scrap metal together first. It's a simple skill, but it still takes a bit of practice to get it right.

well I'm starting to put my riveting instructable together right now. hopefully all will work well since it'll be my first one. for the purposes of this instructble I'm using a roofing nail. on armour i usually use them for attaching leather to steel, for metal to metal i use 6d nails. available for less than a buck a pound at any hardware store.