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How to make armor out of waxed leather scales.

5 - Lace the Scales Together

I bought my lacing from Lee Valley Tools. I'm using their 96lb test nylon cord. I used a spool and a half (75 yards) to make two sets of body armor. I use a lighter to cut the nylon to get that nice fused end.

The knot that I use is just lots of half hitches.

Overview

Here is the whole body laid flat. The back is on the left, the front on the right. This piece will open on the right hand side. The only step remaining is tieing the shoulder "straps" onto the bib front.

I recommend starting by making the long rows that cover your stomach. Just keep adding scales in a row until it goes around you comfortably. Do four of those, stitch together. Then the upper back, the bib front and finally the shoulders.

Sizing is all up to you. This rig is 34 scales around. The upper back is eight scales wide, the bib front is 5 scales wide. The shoulder strap is 8 scales long and the shoulder armor is 5 scales front to back and 3 rows attached to the shoulder strap.

We Begin

Over lap your first two scales. Thread through all four holes and tie a knot. That's already done on the left. Then we start a running stitch. Go through the top hole on both scales, turn around and come back on the bottom of both. Tuck your cord under and then pull tight.

Tie a knot occasionally as you go. If your cord breaks, you'll only have a small gap that you can fix at the END of the day rather then in the middle of fighting.

Below is one row of the upper back. You may notice that I've messed up which way the scales over lap between the above picture and this one. Don't do that. It will look a bit better if everything laps in the same direction.

So, do two rows and then stich them together. Start with your favorite knot (I'm using lots of half hitches.) going through just the two holes in one scale

This is the stitch. Notice how the scales in these two rows overlap differently? Don't do that.

This is the easiest way that I've found to continue the stitch. The new row can pivot out of the way as you work.

This is those two rows all stitched together and viewed from the front.

And here's the back.

Here's the shoulder protection. The top row is laced tightly. All the other rows are laced and stitched quite loosely to allow them to flop down over the curve of your shoulder.

This is the completed project. Now you can clean up the dangling cords and add some way to hold it closed.

The cheap way that I've been closing the armor is to tie some sturdy leather thong onto the back and make a loop on the front. You squeeze your left arm and head into place and then tie the right side closed.

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