Constructing a Lorica Plumata

by Lord Ernst der Dunkelwolf

        Numerous styles of Roman Imperial armor find use in the S.C.A, the coat of mail, lammellar, scale, and the famed lorica segmentata. One known but overlooked armor is the lorica plumata. (The name seems to be derived from the similarity in appearance of this armor to the breast feathers of birds, hence, plumata "plumage" .) Yet this armor can be constructed by most experienced mail-makers; however, I would advise a larger scale than that used by the Romans. The lorica plumata was an expensive officer's armor. It was made by weaving scales into mail, thereby making a scale armor with mail, rather than cloth, as the backing fabric. Archeological examples quoted by H. Russell Robinson have bronze mail links of about 3-4 mm (circa 1/8") in diameter and are riveted shut. The facing scales alternate between iron and bronze and measure about 8 mm x 1 cm. Having attempted to manufacture plumata on this size, I have concluded that there is much to be said for the Roman's use of slave labor in the armor fabrication. A mail-maker with the experience of a few hauberks behind him could make a reasonable facimile of a lorica plumata, but with larger rings and scales. I began with links of 17 gauge electric fence wire wound around a 1/4" dowel. Since the size of the scales is proportional to the size link used, I decided to make scales 1" x 1 1/4" in size. First, the links must be tightly closed. If your cutting tool leaves a gap where you butt the ring closed, the scale will come loose. Therefore, your rings must butt together tightly. (See figure 1)

        Next you must construct the facing scales. These may be of brass, bronze, steel, or a mixture of these materials. I advise using a 22 guage steel that has been tinned or galvanized. Stainless steel could be used if you really want; mild steel may be used if you don't mind cleaning thousands of rusty scales (slave labor?). The scale must be cut similar to figure 2.

        The bottom end should be rounded or cut to an oval apex. A sharp point could prove dangerous to the wearer. Now punch four 3/16" holes in the top of the scale with a Whitney punch. Drill them if you must. The holes' centers should be 1/8" from the top with the outside holes 1/8" from each side and the center holes spaced 1/4" from the outside holes and each other.

        Now bend the top 1/4" of the scale back to form a 90 degree angle (fig. 3). All four holes should lie on a plane 90 degrees to the face of the scale. Finally, take a dull 3/4" chisel and emboss a medial ridge from the back of the scale. Do not crease the scale all the way to the edge. This "corrugation" will strengthen the scale and make it harder to bend or crease with a blow. Let me say now that cutting, punching, and embossing hundreds or thousands of scales by hand is very time consuming. You could save lots of time by having a sheet metal shop make the scales for you, but if you can afford that, then you might want to hire someone to make your plumata for you (slave labor?) . Take it from someone who has made mail shirts from springs at a weekend event; a lorica plumata will take two to three times longer to fabricate than a 1/4" link mail shirt alone. Fabrication time does not include the time it takes to make scales or cut links. If you're going to put this much time into the armor, save your money and use the time.

        Now we come to assembly. First, make a strip of mail three rows deep and as long as you want. Each "row" is composed of rings which are not connected to each other but are connected to the adjacent row. On the fourth row, place a scale face down on the table. Insert a ring through the scale's hole #1 and then link the ring in the two rings in the patch above which follow the pattern of mail. (Rings 1 & 2). Next, place a second ring through the second scale hole, then weave it into the mail (Rings 2 & 3) The third ring goes through scale hole 3 and rings 3 & 4. The fourth ring's placement is slightly different. Place the link through the first scale's fourth hole. Then weave the link through the second scale's first hole. Now weave the link into the mail above (Rings 4 & 5) . Thus each scale overlaps the next scale forming a semi-rigid defense. Without this overlap, the scales gap exposing the mail underneath, but more flexibility is obtained.

        Continue this weaving pattern across your strip of mail . When one horizontal row of scales has been added, add two rows of mail without scales to the which run through the first row of scales. add the seventh row of mail and second row of scales by inserting Links through the scales and into the mail as before. On the inside of this armor. the mail should follow its usual pattern of 4:1; the outside of the plumata will look like scale armor.

        Finally, let me say that it is easier to work from the mail side than the scale side. Also aventails and other fitted shapes can be made using the following method. Place "idler" or "expander" rings as you normally do in mail. Three idler rings per row adds one scale, or 4 idler rings per row for 3 rows yields twelve additional rings every third row and 4 scales. (Figure 3 rings per scale since the 4th hole is always shared. 12 divided by 3 = 4. )

        Although the lorica plumata is time consuming to make, it is a beautiful armor. Learning its method or manufacture also gives mail-makers a chance to test their skill while expanding their knowledge. Perhaps we will soon be able to see one more form of Roman armor in our Lists in the future.

Rear View of Weaving Pattern where two scales are in the second row, a third is being started on row five. Scale: ring= 1/4 inch internal diameter. * Empty hole ready for scale overlap or/and link of mail