How to Cut Leather Scales
Armor made from rows of overlapping scales, often called scale mail, is a popular and relatively easy-to-make form of armor for medieval re-enactors and those looking to add something extra to a Middle Ages costume. The metal scale mail was traditionally made from, however, is both quite heavy and difficult to work without expensive tools. For this reason, as well as for reasons of comfort, leather is a popular substitute scale material.
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Instructions
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Determine the general design for your scales; pointed or round, their size, and if you want to incorporate decorative features. Draw this design, in real size, on your paperboard. The scale should be approximately twice as long overall as the portion that will be visible when the armor is completed, and the covered half of the scale should be in the shape of half of a rounded rectangle or oval. Cut this paperboard scale out carefully with your craft knife.
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Place the paperboard scale on the rough side of your leather and trace around it with a pen or thin marker. Remove the pattern and carefully use the craft knife to cut the scale shape out of the leather. Do not discard the paperboard pattern; use it to trace all the scales you make, rather than tracing around a leather scale, to assure that all of your scales come out at a consistent size. If you trace each new scale with the previous one, your scales may grow slowly larger as you progress or show consistent flaws if any of the scales were cut less than perfectly. When cutting, keep the craft knife as completely vertical as possible, to avoid an unwanted edge bevel.
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Cut or punch one or two holes in the covered end of each scale to accommodate the rivets that will set the scales against their backing. Keep the holes 1/4 inch to 1/2 inch away from the edge of the leather so that the rivets do not tear out of the leather when stress is applied. If there is room, cut or punch two rivet holes side by side horizontally to keep the finished scales from twisting around on the backing.
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