Make Chainmail: A Comprehensive Guide

Aug 27, 2025 by Henrik Larsen 38 views

So, you want to make chainmail? That's awesome! Chainmail, also known as mail or chainmaille, is a type of armor made from interlocking metal rings. It’s been around for centuries, offering protection in battles and looking seriously cool in movies and fantasy settings. But making your own chainmail isn't just for knights and warriors anymore. It's a fantastic hobby, a chance to create something unique, and a skill that connects you to a long and fascinating history. This comprehensive guide will walk you through everything you need to know to make chainmail, from gathering your supplies to crafting your first piece. We'll break down the process into easy-to-follow steps, so even if you're a complete beginner, you can get started on your own chainmail project. Whether you're interested in creating a full hauberk (a chainmail shirt), a small piece of jewelry, or just want to learn the craft, this guide has got you covered. We'll delve into the different materials you can use, the tools you'll need, and the various weaves you can create. Think of this as your ultimate resource for all things chainmail. So, grab your pliers, get ready to coil some wire, and let's dive into the world of chainmail! You'll be amazed at what you can create with a little patience and some know-how. And trust me, the feeling of wearing something you've crafted with your own hands is pretty incredible. So, are you ready to embark on this exciting journey? Let's get started!

What is Chainmail and Why Make It?

Before we jump into the how-to, let's talk a bit about what chainmail actually is and why you might want to make it yourself. Chainmail is essentially a fabric made of metal rings, linked together in a specific pattern. It's strong, flexible, and provides excellent protection against cuts and slashes. Historically, chainmail was a crucial part of medieval armor, worn by knights and soldiers for centuries. It's even been found in archaeological sites dating back to the Roman era! But beyond its historical significance, chainmail has a unique appeal. It's beautiful in its simplicity, and the process of creating it is both meditative and rewarding. Making your own chainmail allows you to connect with the past in a tangible way, experiencing a craft that has been practiced for generations. Plus, it's a fantastic way to express your creativity. You can experiment with different materials, weaves, and designs to create truly one-of-a-kind pieces. And the best part? You don't need to be a master craftsman to get started. With the right tools, materials, and a little guidance, anyone can make chainmail. Think about the possibilities! You could create your own chainmail jewelry, a stunning addition to a costume, or even a full set of armor for cosplay or historical reenactment. Or maybe you just want to learn a new skill and challenge yourself. Whatever your reason, making chainmail is a rewarding and fulfilling experience. So, let's get into the nitty-gritty and explore the materials and tools you'll need to bring your chainmail dreams to life.

Gathering Your Supplies: Materials and Tools

Alright, so you're hyped to make chainmail. The first step is gathering your supplies. Don't worry, you don't need a medieval forge or anything like that. The materials and tools are surprisingly accessible. Let's break it down:

Materials: Choosing Your Wire

The most important material for making chainmail is, of course, the wire. You'll need a lot of it, so choosing the right type is crucial. Here are some popular options:

Mild Steel: This is a great choice for beginners. It's relatively inexpensive, easy to work with, and readily available. Mild steel chainmail is sturdy and looks fantastic, especially when finished with a blackening or bluing treatment. However, it's prone to rust, so you'll need to maintain it properly. It is also very popular for creating chainmail armor.
Stainless Steel: If you want something more rust-resistant, stainless steel is the way to go. It's a bit more expensive than mild steel and can be harder to work with (it's tougher to bend), but the durability and low maintenance make it worth it for many chainmail artisans. Many believe this to be the best option when wanting to make chainmail.
Galvanized Steel: Galvanized steel is mild steel that has been coated with zinc to prevent rust. It's a good middle ground between mild steel and stainless steel in terms of cost and durability. However, some people don't like the look of the zinc coating, and it can flake off over time. This is a good starting point when learning how to make chainmail.
Aluminum: For a lightweight option, aluminum is an excellent choice. It's easy to work with, rust-resistant, and comes in a variety of colors. Aluminum chainmail is perfect for costumes and jewelry, where weight is a concern. Many prefer aluminum as it can still make chainmail for protection but allows for more flexible movement.
Precious Metals (Silver, Gold, etc.): If you're feeling fancy, you can even use precious metals like silver or gold to make chainmail jewelry. This is a more advanced option, as these metals are expensive and require special tools and techniques.

Wire Gauge and Diameter: You'll also need to choose the right wire gauge (thickness) and inner diameter (ID) for your rings. These two factors will determine the density and strength of your chainmail. A lower gauge number means a thicker wire. For most chainmail projects, 16-gauge or 18-gauge wire is a good starting point. The inner diameter of your rings will depend on the weave you're using, which we'll discuss later. A good rule of thumb is to aim for an aspect ratio (ID divided by wire diameter) of between 4:1 and 6:1 for a standard 4-in-1 weave.

Tools: What You'll Need to Get Started

Now that you've chosen your wire, you'll need the right tools to turn it into chainmail. Here are the essentials:

Wire Coiler: This is a tool that helps you wind the wire into a tight coil. You can buy a dedicated wire coiler, or you can make your own using a drill and a mandrel (a metal rod of the desired inner diameter). This is crucial to start the process and make chainmail.
Wire Cutters: You'll need a good pair of wire cutters to cut the coil into individual rings. Look for cutters that are designed for the gauge of wire you're using, and make sure they're sharp for clean cuts. These can also be referred to as flush cutters. It is important to make chainmail rings with a clean cut.
Pliers: You'll need two pairs of pliers to open and close the rings. Chain-nose pliers or flat-nose pliers are ideal, as they provide a good grip without damaging the wire. It is important to make chainmail using two pliers so the rings do not get misshapen.
Ruler or Calipers: These will help you measure the inner diameter of your rings and ensure consistency. This is important to measure when learning how to make chainmail.
Safety Glasses: Always wear safety glasses when working with wire and tools. Metal shards can fly off and cause injury. It's better to be safe than sorry!
Optional Tools: There are a few other tools that can make your life easier, but aren't strictly necessary for beginners. These include a ring closer (a tool that helps you close rings more easily), a tumbler (for polishing your chainmail), and a workbench or other dedicated workspace.

With your materials and tools in hand, you're ready to start making rings! Let's move on to the next step: coiling and cutting your wire.

Making the Rings: Coiling and Cutting

Okay, making chainmail rings might seem a little tedious at first, but it's a crucial step. Think of it as laying the foundation for your masterpiece. The more consistent your rings, the better your finished chainmail will look and feel. So, take your time, be patient, and let's get coiling and cutting!

Coiling the Wire

The first step is to coil your wire. This involves wrapping the wire tightly around a mandrel to create a long spring-like coil. Here's how to do it:

Set up your wire coiler: If you're using a commercial wire coiler, follow the manufacturer's instructions. If you're making your own, secure the mandrel in a drill chuck and clamp the drill in a vise. Make sure the mandrel is securely held in place.
Attach the wire: Secure one end of the wire to the mandrel. This could involve threading it through a hole in the mandrel or using a clamp to hold it in place. You can also create your own system when you make chainmail.
Coil the wire: Slowly and steadily turn the mandrel, guiding the wire as it wraps around it. Keep the wire taut and the coils tight against each other. Overlapping coils will result in uneven rings. This part of learning to make chainmail can take some time to perfect.
Fill the mandrel: Continue coiling until you've filled the mandrel with wire. The length of the coil will depend on the size of your project and how many rings you need. It is better to make chainmail with more rings than not enough so you can complete a full project.
Remove the coil: Once you've coiled enough wire, carefully remove the coil from the mandrel. You may need to use pliers or wire cutters to snip the end of the wire that's attached to the mandrel. Now it is time to learn how to make chainmail rings from coils.

Cutting the Rings

Now that you have a coil of wire, it's time to cut it into individual rings. This is where your wire cutters come in handy. Here's the process:

Position the coil: Hold the coil firmly in one hand and position your wire cutters at the point where you want to make a cut. The goal is to cut the wire cleanly and squarely, creating rings with smooth, even ends. This is an important part of learning how to make chainmail.
Cut the ring: Squeeze the wire cutters firmly to cut through the wire. Try to make the cut in a single, smooth motion. Avoid twisting or bending the wire, as this can create jagged edges. This can become more important when looking to make chainmail armor.
Repeat: Continue cutting the coil into individual rings, working your way along the entire coil. It is recommended to make chainmail rings of a similar size and shape for an even final product.
Inspect the rings: As you cut, inspect the rings to make sure they're uniform in size and shape. Discard any rings that are misshapen or have jagged edges. This step is important to avoid rings from falling out or not lining up when looking to make chainmail.

A Note on Ring Size and Consistency

Consistency is key when making chainmail. The more uniform your rings, the better your finished piece will look and function. That's why it's important to pay attention to the inner diameter of your rings and make sure they're all the same size. Using a ruler or calipers to measure the ID of a few rings from each batch can help you maintain consistency. If you find that your rings are varying in size, you may need to adjust your coiling or cutting technique. Remember, practice makes perfect! The more you coil and cut, the better you'll become at creating consistent rings. And once you have a good supply of rings, you're ready to start weaving them together! This is the most important step to make chainmail.

Weaving the Chainmail: Basic Techniques

Alright, you've got your rings, now comes the fun part: weaving them together to make chainmail. There are many different chainmail weaves, each with its own unique appearance and properties. We'll start with the most common and basic weave: the 4-in-1 weave. This weave is strong, flexible, and relatively easy to learn, making it perfect for beginners. Once you've mastered the 4-in-1 weave, you can explore other weaves and create more complex designs.

The 4-in-1 Weave: A Step-by-Step Guide

The 4-in-1 weave gets its name from the fact that each ring passes through four other rings. This creates a dense, interlocking structure that is both strong and flexible. Here's how to weave it:

Start with four rings: Take four rings and close them. These will be the foundation of your weave. When learning how to make chainmail this first step is important to have a strong foundation to work with.
Add a fifth ring: Open a fifth ring and pass it through all four of the closed rings. This is the key to the 4-in-1 weave. It will bind those first four rings together. Now it is starting to look like chainmail. This is the beginning of the row. This is very important when you want to make chainmail armor, as this will be done over and over again.
Close the fifth ring: Close the fifth ring securely. You should now have a small cluster of five rings, with one ring connecting the other four. This is called a unit.
Repeat to create a row: To create a row of 4-in-1 weave, you'll need to repeat steps 2 and 3. Open a new ring and pass it through two rings from the previous unit and two new rings. Close the ring. You should now have two interconnected units. Repeat this process to create a row of the desired length. A longer row will help get you started when you make chainmail armor.
Start the next row: To start the next row, you'll need to connect it to the previous row. Open a new ring and pass it through two rings from the first row and two rings from the second row. Close the ring. Repeat this process to create the second row. Connecting the rows is what really turns this in to a protective sheet of chainmail.
Continue weaving: Continue weaving rows together, connecting each new row to the previous row, until you've created a piece of chainmail of the desired size. This is what will create the pattern of the chainmail. When you make chainmail armor it is important to weave tightly to prevent gaps.

Tips for Weaving Success

Use two pairs of pliers: Using two pairs of pliers, one in each hand, makes opening and closing the rings much easier and prevents them from becoming misshapen. This is the most efficient way to make chainmail.
Work in a well-lit area: Good lighting is essential for seeing the rings clearly and avoiding mistakes. This is important as you progress and make chainmail armor.
Take breaks: Weaving chainmail can be tiring, especially for your hands. Take breaks as needed to avoid fatigue and prevent injuries.
Don't be afraid to make mistakes: Everyone makes mistakes when they're learning a new skill. If you mess up, don't worry! Just undo the rings and try again. Learning to make chainmail will take practice.
Practice makes perfect: The more you weave, the better you'll become. Don't get discouraged if your first attempts aren't perfect. Just keep practicing, and you'll soon be weaving chainmail like a pro.

Beyond the 4-in-1 Weave

Once you've mastered the 4-in-1 weave, you can start exploring other chainmail weaves. Some popular options include the European 6-in-1 weave, the Japanese 4-in-1 weave, and the Byzantine weave. Each weave has its own unique appearance and properties, so there's plenty to discover! You can also experiment with different colors and materials to create unique designs. The possibilities are endless when you make chainmail!

Finishing Touches: Cleaning and Maintaining Your Chainmail

Congratulations! You've woven a piece of chainmail. Now, let's talk about finishing touches: cleaning and maintaining your creation. Proper care will ensure that your chainmail looks its best and lasts for years to come.

Cleaning Your Chainmail

Depending on the material you used, your chainmail may require different cleaning methods. Here are some general guidelines:

Mild Steel: Mild steel is prone to rust, so it's important to keep it clean and dry. You can clean mild steel chainmail with a mild detergent and water, then dry it thoroughly. You can also use a rust inhibitor to protect it from moisture. This is the most difficult part of learning to make chainmail with mild steel.
Stainless Steel: Stainless steel is more rust-resistant than mild steel, but it can still get dirty. You can clean stainless steel chainmail with a mild detergent and water, or with a specialized stainless steel cleaner. This is why many people choose to make chainmail from stainless steel.
Galvanized Steel: Galvanized steel can be cleaned with a mild detergent and water. Avoid using harsh chemicals or abrasive cleaners, as these can damage the zinc coating. While this is the least likely metal used to make chainmail it still needs to be cleaned properly.
Aluminum: Aluminum chainmail can be cleaned with a mild detergent and water. You can also use a polishing compound to restore its shine. This is also a lower maintenance option to make chainmail with.
Precious Metals: Precious metal chainmail should be cleaned with a specialized jewelry cleaner. Follow the manufacturer's instructions carefully. This is not a common option to make chainmail, so it is important to follow instructions.

Tumbling: A Powerful Cleaning Method

For heavily soiled or tarnished chainmail, tumbling can be a very effective cleaning method. Tumbling involves placing the chainmail in a rotating drum with a cleaning media, such as stainless steel shot or ceramic beads. The tumbling action polishes the rings and removes dirt and tarnish. Tumbling is a common step when people make chainmail armor.

Maintaining Your Chainmail

In addition to cleaning, regular maintenance can help keep your chainmail in good condition. Here are some tips:

Store it properly: When you're not wearing your chainmail, store it in a dry place, away from moisture and direct sunlight. This is especially important when you make chainmail armor that is larger and heavier.
Inspect it regularly: Check your chainmail for any damaged or broken rings. Replace any damaged rings as soon as possible to prevent further damage. This can be a time consuming process, but is very important when you make chainmail armor.
Oil it (for mild steel): If you've made chainmail from mild steel, applying a light coat of oil can help prevent rust. Use a rust-inhibiting oil and apply it sparingly. This is what requires more maintenance when you make chainmail with mild steel.

With proper cleaning and maintenance, your chainmail will not only look great but also last for many years. You've put in the effort to make chainmail, so now it is important to care for it.

Conclusion: Your Chainmail Journey Begins!

And there you have it! You've learned the basics of how to make chainmail, from choosing your materials and tools to weaving the rings and maintaining your finished piece. It's a journey that combines craftsmanship, history, and a touch of medieval magic. Remember, the key to success is practice and patience. Don't be afraid to experiment, try new weaves, and put your own creative spin on things. Whether you're crafting a stunning piece of jewelry, a unique costume element, or even a full set of armor, the possibilities are truly endless. So, embrace the challenge, enjoy the process, and let your imagination run wild. Welcome to the world of chainmail – your adventure has just begun!