The Armour Archive

I'm making my 1st helm (a bascinet) from an ironmonger kit. (Mild steel)

What tool should I use to 'smooth' the edge around the face ? I was thinking a die grinder might work. If so, what bit should I use?

I usually just use a big file for stuff like that.

Second the notion. Also pluralize it: files. Two shapes: a flat, or mill, file for helping the straight edges stay that way; a half-round file also, for the rounded corners up top.

A bit slower than a die-grinder I guess; less sparky; also less likely to gouge too deep into anywhere -- harder to make a mistake with a hand tool.

Just how chewed up is this edge, anyway? Did you use a saw?

If using a die grinder or other rotary tool my first choice in bits would be a small sanding drum; if not that then one of those abrasive/stone grinding bits.

Konstantin the Red wrote:Also pluralize it: files. Two shapes: a flat, or mill, file for helping the straight edges stay that way; a half-round file also, for the rounded corners up top.

I guess I do have a pretty good collection of files. I find that the half round also do nicely on inside curves such as you'll have along the inside of the brow line of the face opening; and the flat files do better on the outside of curves.

I agree. Always learn on the slower methods. Much harder to make a mistake and you get a much better feel for how the piece should look and feel. If you're so inclined ( and a little bit masochistic), get a set of needle files to do some detail work after the edge is just how you would like it. I love alternating between a triangle and a round to get a nice look myself...

I would start by useing masking tape to distinguish your line.

I would consider an old sanding disk on the angle grinder depending on how much stock you have to remove.
Files are a good option if you are with in 1/8" or so.
If your useing power tools make sure you have a good solution to holding the work.

"If you don't hold your work your work will work you."

"Power tools let you make mistakes faster."

Steve

"Grinders are flesh eating monsters."

I dunno, guys, whereas I'm a big, big fan of the files (they often actually work just as quickly as a power tool would, provided you know what to do with them), this is one case where I wouldn't reach for them.
The main reason is because files are part of a two-tool solution. The other half is the vise. And I don't have a vise that I can put a helm in, without causing more problems than I'm solving.

I would use a die grinder, sure, or similar. I would make sure it's not going insanely fast, and I would probably use a floppy tool like a fiber disc.
If there was a lot of cleanup, like an extra 1/4" on one side of a weld, I would use a hard wheel for that, but the final shaping would definitely be a soft tool.

Look at your vice/bench a little closer, auxiliary jaws can be formed from pine, rubber, and hard foam while still gripping the work.

The holes for the bench pins can also be used like the hold downs for mill, like a stitching pony, or like a shaving horse.
All you need is a long enough lever and a place to stand.
V blocks, hold fasts, and bench pins work well for holding odd shapes.

Konstantin the Red wrote:Second the notion. Also pluralize it: files. Two shapes: a flat, or mill, file for helping the straight edges stay that way; a half-round file also, for the rounded corners up top.

A bit slower than a die-grinder I guess; less sparky; also less likely to gouge too deep into anywhere -- harder to make a mistake with a hand tool.

Just how chewed up is this edge, anyway? Did you use a saw?

When the two helm halves were put together, they didn't quite match up. So there is a bit of material to file down.

I also need to trim the side/back piece and blend it into the top.

What does everyone use to 'blend' the weld line?

I like to start off with a flap disk on my angle grinder and then finish up with a hard disk. Then polish.

schreiber wrote:I dunno, guys, whereas I'm a big, big fan . . . files are part of a two-tool solution. The other half is the vise. And I don't have a vise that I can put a helm in, without causing more problems than I'm solving.

I'd build a suitable wooden claspy thing, probably using a C clamp or pony clamp (hey, I can clop this armor!) to tighten its grip with -- and shove the bottom end of the whole affair into the jaws of the bench vise, arranging for the bottom end to ground out on either the bench top or with a long leg to the floor. Floors are very good at holding things up. Particularly with a leg to stand on.

Konstantin the Red wrote:

schreiber wrote:I dunno, guys, whereas I'm a big, big fan . . . files are part of a two-tool solution. The other half is the vise. And I don't have a vise that I can put a helm in, without causing more problems than I'm solving.

I'd build a suitable wooden claspy thing, probably using a C clamp or pony clamp...