Each wall consists of at least 12 layers of cloth (cotton linen), overlappings adding layers in preplanned areas, making the armour substantially stronger there. It is not necessary to vary the alignment of the clothīs warp during manufacture of the layers, you only do that with armour made of quilted fabric. I used black cloth; this is least noticeable in case of colour abrasion.
The minimized contact surface together with the arched areas of the armourīs under layer permits to largely dispense with isolating padding, thus allowing air circulation under the armour. Whoever enjoyed this luxury on a hot battlefield never again wants to go without it! This and the armourīs weight of under 7 kg make it very well suited for use in hot climate.
The side plates covering the upper arms are non- removable and arched like the other components. To save weight and volume they look like a silhouette of Africa instead of being rectangular or crest- shaped. In their main- impact- area a second arched plate rests on a layer of padding; that way implementing the two- tier- principle. The undergarment again is padded on the upper armīs outer sides.
Of course this construction is way more complicated than a classical greek/ roman linothorax. The reasons for taking the long route were:
- my desire for minimized contact surface (meaning air circulation and cooling) together with more body coverage than the originals
- the materialīs processing options: plate shears can cut only up to about 10+ layers but I wanted more than twice as much
- the armourīs design to better be able to resist heavy blunt impacts than the originals
and eventually the wish to find a shape for the armour that as much as possible differs from euro- antique examples: this is a chaos warriorīs armour and thus authorized to “look different”.
Iīm talking so much about the function of the armourīs individual components because otherwise one would reasonably have to ask why I didnīt just copy an approved and reliable construction like a “Lorica Segmentata” (the roman legionaireīs metal- armour) or build a “tube- and- yoke- armour” like a greek Linothorax; both would have been way less time- consuming and complex.
Well, in fact the project got a little out of hand with me coming up with more and more possibilities for using this amazing material. Its unique way of manufacture grants much more freedom than metal or leather, all the while needing almost no tools, know- how or soundproof workshops. You can in fact work in your living- room.
Which I did over a period of almost three months...
Whatever. Back to topic. The helmet was ready which is necessary for trying it on together with the harness over and over again to make sure the equipment doesnīt lock or becomes entagled.
Step one 1: Mould making; encore une fois...
Below: the harnessī bottom wall made of cardboard and tape.