How do you make a chainmail suit out of #10 copper wire?

Question

My grandfather and I are in a skirmisher's club. This is a club where we fight using spears, swords, daggers,etc... most people at the club use armor of sorts, (the weapons are really sharp!) my grandfather says you can make chainmail out of #10 copper wire. is this true if so, how? need to figure this out soon. also, what should I use as tips for my spears? what makes a great blade for swords and daggers and such?

Answer 1

First of all, don't use copper. It won't rust, but it is terribly dense and also far too soft to be of any use. What you want is good carbon-steel wire. For an average shirt of maille, with 3/8" interior diameter rings, you will need about 10,000 to 12,000 rings. This will mean about 15 to 35 pounds of wire, depending on the size and length of your shirt.

These will be hooked together in a pattern where four rings go through a fifth, what is known as the 'four-in-one' pattern. There are many sites on the Web where you can find illustrations of the pattern, look for the term 'maille'. The rings are generally made by winding the wire around a steel rod like a spring, then slipping the rod out and clipping off the rings with a wire cutter.

Before you run out and start buying wire, decide if you have the time and patience to do this. At several hours a day, it will likely take you at least 4 to 5 weeks to complete, and that's assuming that you know what you are doing - otherwise, it will be even longer.

You may be better off simply buying a shirt from a maille maker. Costs can run anywhere from $200 to $1000 US, but at least you'll have a finished product rather than a half-completed project. Many places on the Web sell maille; look for "arms and amor" or "medieval armor" or just "maille".

If you want to learn how to fight with swords, don't try to make your own. Learn from a qualified instructor, and do it right. Swords are not toys, they are real weapons, and people can easily be hurt or killed by them,even when they "aren't sharp".

Answer 2

You can Buy High Quality Chainmail Shirt at very very affordable price at :
http://www.armorshopusa.com/en/medieval-chainmail-shirts/

Answer 3

I wouldnt use copper, it will rust very quickly and turn green.

but basically you just make a bunch of small rings out of the wire, and link them together.

Answer 4

I'm not sure the exact procedure, but you might also consider alluminum wire. It would be lighter.