Step 2: Making the Scales

making the scales in easy but it gets kind of monotonous after a while. first you cut small rectangles out of the larger sheet of metal. i found the best way was to cut 2 inch strips out of the sheets. then i cut the strips in half then the halves in half. and continued doing this until i had a bunch of pieces about 2inches by 1-1/2 inches.

then you cut the pieces in to scale shape hammer out the sharp parts made by the tin snips if there are any. then you poked holes through the corners with the large nails. after this you hammer the hole flat so its not sharp. but this can mess up the hole so then you have to  repunctured the scale in the same hole then hammered it again. this gives you a good hole in the scales that shouldn't cut the wire later.
Would there be any foreseeable issues with using aluminium sheet rather than steel? It would be cheaper and lighter, surely.
thats dumb
For hammering the helmet, try buying a baseball batting helmet at a thrift store or second-hand sporting goods store (rather inexpensive). You could heat the metal with a torch but it would probably melt the batting helmet as you were working. Or just try cutting the batting helmet to the shape you want and adding a nice paint job.
The shield is quite good, with a miner exception. In the movie, the shields have a hole in the wood behind the boss, and a single, vertical wooden handle right behind that, which goes all the way across the shield. But with that change, and your armor, that is one amazing costume.
&nbsp;hi there,<br /> now im on a low budget so i was wandering how much the metal that you used would cost?? Recently i have been collecting soft drink cans so do you think that the aluminum in those would be suitable substitute?<br />
on the vest i used about 780 square inches of metal and at lowes you can get a 24&quot;/48&quot; sheet, witch is 1152 square inches, for about 27$ but that's just the vest<br />
it would also depend on how big you are<br />
For Rohan we must not fail<br />

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