Genuine chainmaille from pop tabs

Constructing a genuine European 4 in 1 chainmaille weave using only pop tabs.

Turns out this is very easy and makes a really great looking piece of maille, and as an added bonus you don't have to worry about having a quarter mile of wire on hand to attach them together.

Step 1: Assemble your supplies

OK, you are going to need lots and lots of pop tabs. Don't give yourself renal failure trying to drink them all yourself. Spread it out or enlist the help of your family, friends, workmates, or maybe even the local recycling center. Here is what you will need:

Cutters
Staple remover
Old key
Non-mangled pop tabs (however many you need, 1000 is a good start)

Step 2: Prepare the tabs

You will need to prepare the tabs for the weaving. Bend the collar down from the "top" side of the tab using the tumbler side of the key. Then use the back of the key to continue bending it down against the side of the tab. Lay the tab face down and push the cupped part down flat.

Step 3: Cut

Now that all your tabs are flat and consistent, you need to cut and crimp them.

Cut them in the very middle of the pull part of the tab, or for a stronger connection, on the rivet side, either way just be consistent.

Step 4: Bend

The tabs will need to be bent slightly so they will lay together properly. This is where the staple remover comes it. Turns out it gives it just the right amount of bend. Put the tab in cut side first and close the tool down so that one side holds the cuts and the "bridge" is over the metal edge on the other side. Press with your finger and, bam! you're done.

Step 5: Repeat

Keep making the links, do them all at once, do them in batches. Either way, its pretty easy to make them.

One note: If you are using cutters, you can bend the tabs first, if you are using scissors you have to cut them first.

Step 6: Weave

Now that you have a massive pile of tabs ready, you will begin the weaving. The first picture shows 4 links woven together in the traditional European 4 in 1 style. The next photos show the proper way to connect them together.

Holding one tab by the back, with one hand, take another tab with your free hand.
Push the back of the second tab through the cut on the first tab from the bottom so that it is on one side.
After they are connected together do the same with a second tab, but on the opposite side.
The fourth tab you put on will connect the two "shoulder" tabs together.
Connect the fourth tab so that the second and third are laying one on each side.
The back of the tabs should always end up on the bottom side of the weave.

Step 7: Continue weaving

Keep doing this until you have reached the desired size. I won't go into detail in this Instructable regarding how to make a specific garment or item. But I will give you some tips on weaving. Because of the pattern, you have a couple different "fabric" geometries you can work with.

The first is the diamond geometry, each link is connected to 3 others
The second is the square, each link (except those on the edges) uses pattern's full 4 to 1 connection

As your swatch gets larger it might be easier to flip it over to continue weaving, because you will need to handle the main body less as you attach new links.

Step 8: Final thoughts

I hope you enjoyed this instructable, it is the first I've written. I still have alot more tabs to go before I will be able to finish anything. I will probably make a pixane, and create a new Instructable for it. I will leave you with some pictures of this cool looking chainmaille.

Comments

[timothymh]

 I really need to make this wider; it keeps folding in on itself as I work. Takes five minutes to straighten out like in the photo below.

[frenzy]

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[Oragami]

I now have something to do in my spare time (thanks to Isa for posting a link to this on her Tumblr :D)

[cybercapri]

Wow, what a great way to make aluminum chainmail, thanks for sharing.

[lycoris3]

this is one of my favorite instructables, and am thinking about collecting to make a nice bag and decoration for a jacket. looking forward to the fun!

[raen714]

After three years (most of which was gathering supplies), I finally have a wearable hauberk. http://stitchesandstringtheory.tumblr.com/post/38606574227/chainmail-hauberk

[Delo97]

I'm going to use this for airsoft battles

[LuciferJr]

it probably wont work well seeing that there are a lot of holes in it

[Delo97]

Ok, but I think I'll use two sheets for them to have one to cover the other

[ilpug]

Huge amount of work for something that is structurally weak and a tactical nightmare. If you need armor, wear a jacket. If you need more, wear two jackets. If you need still more, then play Nerf instead. This mail is awesome, but it really won't help on the field. Maybe as a little decorative patch on the back of a glove or something, but that is about it.

[Delo97]

Well, I just want something for non-professional, friendly battles. I am currently using cardboard.

[deceasedparrot]

cardboard works ok for this, a duct tape vest is better. if you dont want to put a lot of time into a duct tape garment, i suppose you could just put one or two layers of tape on the cardboard. or just wear a sweatshirt with a hood.

[triforceftw]

My chainmaille tends to come apart because of the slit that is needed to attach them together. Is there any certain way I can seal it or keep the maille from coming undone? Thanks :D

[scornn]

should be able to solder it you might need extra flux

[EVIL STICKMAN]

wow wonderful design but is it only for show or can you actually use it for something like maybe putting two layers or more of it so it makes arrow proof armor or somehing

[arpoky]

At this stage, I find that just pinching the tabs a few times with the pliers helps to get a good, center cut. I also found that bending the tabs before cutting them doesn't make the cut side turn out so bent out of shape.

I actually tried this a few years ago, and I am now making another attempt at it. I want to make a shirt for a Link Cosplay I had in mind.

[Kzummo]

Right now i'm making a chainmail head mask

[Tim_C]

I know this is a really old instructable, but someone might read it. Depending on the way you prefer to join the links you only need to cut half the rings. I just crimp all of mine and cut only what I need before I start a 'mailling' session. I am sure it would increase strength too.

[jedijaxson]

Just break the rivet collars off by bending them back and forth. Works for me!

[Kianon]

heh, to me it looks like a combination of chainmail and scalemail.

[GDfense26]

are there any other methods that will bend them just as consistantly without using a staple remover?

[NinjaGuy000]

I've been using a normal pair of Needle nose pliers.

[Gelfling6]

It's worth a shot.. When I've been making standard ring maille, I use a pair of 'Duck-Bill' long-reach pliers from Sears.. (Item# 00945087000 | Model# 45087 ).. they have a wider width jaw than needle-nose pliers, about 5/16" width.. they might be about the right width to grab each tab, and use the other (or even a pair of lineman's pliers) to make the bend. I will say, from someone who's made chain maille for close to 28 years, I am impressed by this! Yes, it would take a L-O-N-G time to make an entire suit of these.. the present suit I wear to ren faires, is 14-guage FyShock aluminum electric fence wire. (well past 4000 rings!) it takes lots of patience, and persistence to complete.

[Delo97]

Ok, but it takes FOREVER to put in precisely

[bdunni88]

I use an adjustable wrench, make it just wide enough to slip a tab inand out and duct tape the worm gear at that position.  I got prettygood at it.  If you want to see the finished shirt you can checkout my instructable

[darknessfalls]

same here

[ironsmiter]

I've made a small jg out of a 2x4(2 pieces) and a door hinge.
I line 3 up side-by-side in the groove   I cut.
then pull down on the "handle" and insta-bent tabs.

[hintss]

right angle edge of needle nose pliers

[Coliflower]

Yes. What I do is I hold one end on a table with the palm of my hand, and have the other half off of the table. then, I just push down with my thumb. But, if you do this, cut after bending.

[Neko-Otaku]

wow, I was recently thinking of making something like this, but I guess you beat me to it :)

[Dusk Shadows]

this must have taken ages

[themoose64]

how heavy is it?

[cajundood]

AWESOME AWESOME. I ENJOY GOING TO RENAISSANCE FESTIVALS AND WOULD LOVE TO HAVE A CHAIN MAIL. (oops caps) but the venders usually want a fortune for them. But I do understand the time & effort it takes to create one of these, so i will begin collecting the tabs and hopefully there will be some patterns that i can go by to make my own chainmail. once again....KUDOS to you!!!

[Shadow Ranger]

This is impressive...I would have never thought of using pop tops for chain mail! You must have drank a lot of soft drinks to get all those! :) 

[Grinch227]

I'm going to use this technique to make a hacky sack or footbag, thanks for the idea!

[Zetainex]

Really thank you, I'm building my own armor with your method, when i have it I'm going to try to post a photo of it. Greetings from Spain!

[MusicMaid]

i think im doing this wrong... ive got like a diamond shape but its curving upwards and whatever i do it wont stop curving upwards..

[quixotiCfluX]

It sounds like you might be making the connections from the wrong side of the work. Can you post a pic?

[th30be]

I found that this way of making chain mail is very annoying because it gets tangled so easily but I found a good solution to it. I use duct tape and stick the tabs I am working on and then when I am done remove the tab. This way you don't spend 10 min untangling them.

[th30be]

I mean remove the tape.