The "Solid" Mantle

I'm not sure what you actually call this, so I came up with the "solid" mantle. It's similar to a maille mantle, the difference being the material it is made of. This mantle doesn't offer any real protection, so it is strictly for costume use. Although if you wanted to you could use a stronger steel to make it and it might protect you from something.

To make my version of the "solid" mantle, go to the hardware store and buy some aluminum sheeting. It's fairly cheap, and it comes on different sized rolls. You'll want one at least 20" wide. The roll I bought was 20" wide and 10 feet long, and costed around $8. The type of aluminum you want for this project is fairly thin and easily bent, and it doesn't rust. Next thing you'll need is something to cut it with. A sharp knife or utility blade will do fine, but I prefer a pair of metalworking shears. I found that a good pair of scissors will also cut the stuff, but it dulls the blade after a while.

After you have everything, you can cut out one of the patterns below. This one was sized for me, but it seems to fit a wide range of people. If it seems to small or too large, just adjust it to fit your needs. Right now you should also decide whether you want to leave a small margin around the edge of the mantle. If you do, later on you can fold it over and it gives a better look.
solid mantle diagram

If you left a margin around the edge, now's the time to fold it over. Make slits around the edges every few inches and bend over the extra aluminum you left. This leaves a nicer looking edges, and the finished mantle retains a better shape. If you didn't leave a margin, you should sand or file around the edges to remove any burrs and give it a better look.

Here's the fun part. Now you have to bend the aluminum into shape. This is easily accomplished with no tools but your hands. Just bend it into an upside down "U" shape. Just keep working it with your hands until you get the right shape. It's OK if it tapers inwards a little (a lot even) since the aluminum has some spring-like properties. It will bend out and when you put it on it springs back giving a nice tight fit. You should end up with something that looks like this: solid mantle

Just slip your head through the hole and you have a nice looking mantle. You might have to rotate it a little or bend it outward some while putting it on so your head fits in the hole. This is an alternative to a maille mantle which takes a lot more time to make. Now you can decorate it and do whatever you want. You probably don't want to leave it plain unless it is real thin in the front with no room for a design of some sort. One of mine has a phoenix on it, and another I covered with cloth and some gold trim. Then I attached a cape and it looks very royal like. You can also experiment with other shapes besides just a basic ellipse. Or if you want some real protection, you can hammer it out of 14 or 16 gauge steel.