# Sovereignty Module: Plate the Body

## Complete Armor Making: From Sheet to Shield

Armor making combines sheet metal work, riveting, and articulation. This campaign covers armor types, plate forming, riveting, articulation, and padding.

### Chapter 1: Armor Types

| Type | Material | Protection | Weight | Mobility | Difficulty |
|---|---|---|---|---|---|
| Padded (gambeson) | Linen/wool layers | Low-moderate | 5-10 lbs | Excellent | Low |
| Mail (chainmail) | Wire rings | Moderate-high | 20-30 lbs | Good | High (tedious) |
| Scale | Small plates on fabric | Moderate | 25-35 lbs | Good | Moderate |
| Brigandine | Small plates riveted in fabric | High | 20-30 lbs | Good | Moderate-high |
| Plate (partial) | Large steel plates | Very high | 15-25 lbs | Moderate | High |
| Full plate harness | Articulated steel plates | Maximum | 40-60 lbs | Moderate | Very high |

### Chapter 2: Plate Armor Basics

Materials: 1) Mild steel sheet: 18-20 gauge (0.040-0.048 inch) for most armor. 2) Medium carbon steel: 16-18 gauge for high-impact areas (breastplate). 3) Hardened steel: heat-treated for maximum protection (advanced). 4) Brass or copper: decorative elements, trim. 5) Leather: straps, padding attachment, articulation.

| Armor Piece | Gauge | Coverage | Difficulty |
|---|---|---|---|
| Helmet (basic) | 16-18 gauge | Head | Moderate-high |
| Breastplate | 16-18 gauge | Chest | High |
| Backplate | 18-20 gauge | Back | Moderate-high |
| Pauldrons (shoulders) | 18-20 gauge | Shoulders | High (articulated) |
| Vambraces (forearms) | 18-20 gauge | Forearms | Moderate |
| Greaves (shins) | 18-20 gauge | Lower legs | Moderate |
| Gauntlets (hands) | 20-22 gauge | Hands | Very high |

### Chapter 3: Plate Forming Techniques

| Technique | Tool | Purpose | Application |
|---|---|---|---|
| Dishing | Ball stake + hammer | Create concave curves | Helmets, breastplates |
| Raising | Raising stake + hammer | Form deep shapes from flat | Helmets, cups |
| Planishing | Flat stake + planishing hammer | Smooth surface | All pieces |
| Fluting | Fluting stake + hammer | Create ridges (strength) | Breastplates, greaves |
| Edge rolling | Edge roller or hammer | Roll edges (safety, strength) | All edges |
| Riveting | Rivet set + hammer | Join pieces | All assembly |

Dishing process: 1) Cut plate to pattern (add 1 inch margin). 2) Anneal plate (heat to dull red, air cool). 3) Place plate over dishing form (concave wood block or sandbag). 4) Strike with ball-peen hammer from center outward. 5) Work in concentric circles. 6) Anneal again when plate becomes work-hardened. 7) Repeat until desired depth is achieved. 8) Planish (smooth) on flat or curved stake.

### Chapter 4: Articulation and Assembly

| Joint Type | Method | Allows | Use |
|---|---|---|---|
| Rivet (fixed) | Permanent rivet | No movement | Fixed joints |
| Rivet (sliding) | Rivet in slot | Linear sliding | Lames (overlapping plates) |
| Rivet (pivot) | Rivet as pivot point | Rotation | Visors, arm joints |
| Leather hinge | Leather strip riveted to both plates | Bending | Gauntlets, sabatons |
| Buckle and strap | Leather strap with buckle | Adjustable closure | Attachment to body |
| Lacing | Cord through holes | Adjustable, flexible | Attachment, closure |

Articulated pauldron (shoulder): 1) Cut 3-5 lames (overlapping plates) from pattern. 2) Dish each lame to match shoulder curve. 3) Overlap lames by 1/2-3/4 inch. 4) Drill rivet holes in overlap area. 5) Install sliding rivets (rivet in slot allows movement). 6) Each lame slides over the one below. 7) Assembly allows arm to raise and lower. 8) Attach to breastplate with leather straps.

### Chapter 5: Padding and Fitting

| Padding | Material | Thickness | Location | Purpose |
|---|---|---|---|---|
| Arming cap | Padded linen | 1/2-1 inch | Under helmet | Comfort, shock absorption |
| Arming doublet | Quilted linen/wool | 1/4-1/2 inch | Under all armor | Comfort, prevents chafing |
| Leather liner | Leather strips | 1/8 inch | Inside helmet | Suspension, ventilation |
| Point ties | Linen cord | N/A | Arming doublet | Attach armor pieces |

### Reference Card

1. Anneal frequently (steel work-hardens as it is hammered; annealing (heating to dull red and air cooling) softens it for further forming; failing to anneal causes cracking). 2. Dish from center outward (when forming concave shapes, start hammering at the center and work outward in concentric circles; this prevents wrinkles and uneven thickness). 3. Articulation allows movement (overlapping plates connected with sliding rivets allow the armor to move with the body; without articulation, plate armor would be rigid and immobilizing). 4. Padding is essential (armor worn directly against the body causes bruising and chafing; a padded arming doublet absorbs shock and distributes the weight of the armor). 5. Weight distribution matters more than total weight (well-fitted armor distributes weight across the shoulders and hips; poorly fitted armor concentrates weight and causes fatigue). 6. Roll all edges (raw-cut steel edges are sharp and dangerous; rolling or turning edges prevents cuts and adds structural strength to the plate). 7. Fluting adds strength without weight (ridges pressed into flat plates dramatically increase stiffness; a fluted breastplate can be thinner and lighter than a smooth one of equal strength). 8. Armor making is the highest form of sheet metal work (forming complex three-dimensional shapes from flat steel, articulating them for movement, and fitting them to a human body requires mastery of every metalworking technique).