Nice job RR_Raptor65. Looks like it paid off rather well.
What exactly does the Planishing process involve? How simple/easy is it?
It's very simple. A lightweight hammer with a large flat face is used, today these hammers are known as auto body hammers, they are virtually unchanged from the original medieval period tools. Planishing is accomplished by putting the unplanished armour over a hard work surface with a convex face, in this case I used a large sledgehammer head. I also used a laser to point at the center of the work surface so I always know where the center is when the piece is on top.
[Img]http://i.imgur.com/1KuBf.jpg[/Img]
Then I just hammer on the piece, every single square millimeter of the armour has to be hammered for the planishing to be effective. Planishing also compresses the metal, making it a bit harder. Luckily the hammer leaves a small shiny spot on the metal so you can see where you've been already, and the effect the planishing process has on the armour is immediate, nothing else is needed other than a quick polish once the planishing is done.
I polished the armour with a wire brush, 600 then 800 grit sandpaper, then a scotchbrite pad. It's not a particularly shiny finish as you can see but I like it both because it's not overly reflective and it's very easy to maintain in the case of rust formation.
Started work on a helmet. I didn't take many pictures early on because I wanted to get through the dishing as fast as possible for an enormous Halloween party on Saturday, but now that the dishing is done I'm confident I'll get the helmet done by Wednesday at the latest.
Here is the helmet, dishing complete and ready for final cutting and assembly.
[Img]http://i.imgur.com/OxHI3.jpg[/Img]
Here is a big plywood mould I made specially for this helmet, after getting the helmet halves ~40% dished they could be placed in here and hammered down into the mould to achieve the correct shape with very little effort.
[Img]http://i.imgur.com/HY825.jpg[/Img]
Folding the edge of the brim.
[Img]http://i.imgur.com/MyetJ.jpg[/Img]
[Img]http://i.imgur.com/x1fsx.jpg[/Img]
[Img]http://i.imgur.com/Cb1j4.jpg[/Img]
Cutting the oversize helmet half to the correct size and shape.
[Img]http://i.imgur.com/RIhzg.jpg[/Img]
I designed the comb to be welded on for this one, the shape of the helmet is extremely important and I didn't care to be arguing with the steel over the angle of the comb versus the width of the helmet.
The welds are intentionally exaggerated to fill in any pockets and provide enough material to grind the edge clean.
[Img]http://i.imgur.com/XtqSo.jpg[/Img]
[Img]http://i.imgur.com/7wpby.jpg[/Img]
Next the two halves will have the bottom edge ground, the whole thing planished and then finally welded into one solid piece, ready for the suspension and chinstraps.
[Img]http://i.imgur.com/cHCNZ.jpg[/Img]
[Img]http://i.imgur.com/Bq5dW.jpg[/Img]
My design is a little different from the kind of Morion you might be used to seeing, it has a less extreme curve on the bottom edge with a downward sloping brim and the comb is short and sturdy. These helmets were extremely common and came in every shape and size you can imagine, along with a few you might not imagine.
Done. Now I need to make some apostles, though my belt grinder took a dive so that will have to wait.
[img]http://i.imgur.com/BXpo7.jpg[/img]
[img]http://i.imgur.com/GcplW.jpg[/img]
[img]http://i.imgur.com/JP0KI.jpg[/img]
[img]http://i.imgur.com/WYTKN.jpg[/img]
man, that looks really slick. i like the metal plates on the chin strap. even though it's just a small thing to make it gives them some details and make them look much better than if they were just plain leather. certainly inspiring work.
[QUOTE=Beanz;32785316]man, that looks really slick. i like the metal plates on the chin strap. even though it's just a small thing to make it gives them some details and make them look much better than if they were just plain leather. certainly inspiring work.[/QUOTE]
Yeah, the plates actually had a functional purpose as well, they protect against sword slashes.
ah well that makes sense. i also got this this perhaps mad idea of how you could cover the edge of the brim on the morion with brass. it might be historically incorrect and look awful but i just love seeing the contrast between the metal coloured steel and brass. it would probably be better suited for other helmets, but brass details (in my eyes at least) makes armor pieces look cool. again, awesome work on the whole ensemble.
Awesome work my friend!
~musketeer swag~
Is that hardie on your anvil 45°? That looks of Chinese manufacture.
Whether it is or isn't, it's a ringer and that's what counts. Need to resurface it though.
-snip nevermind-
So nothing new?
Not yet, have to start over and I'm not quite ready to start from scratch again.
Raptor, do you do any hotwork, is the sword hardened and tempered at all?
The sword was forged, I had to draw it out until it was long enough as the piece I had was too short to be a good sword. It's just a matter of grinding it right now. It'll be tempered in some canola oil before I'm done.
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