I'm only posting this because I've never heard of these tools mentioned by the pro's on this board.
Having worked in a sheet metal (HVAC) shop for several months, many years ago, I have some idea of how to at least get the lamellar plates cut efficiently and without power equipment. Of course this would work best if you are going for the "home plate" shape of lammelar but makes a good starting point for any shape regardless.
A foot operated straight shear with a backstop. Your typical sheet metal worker would be able to whip out hundreds (if not more than a thousand or two or more) in a day. This tool stands alone on the floor, comes in a variety of widths and, ideally, the backstop is easily adjustable.
A 4 x 8 ft sheet could be whacked into 3.5 in x 4 ft (or 4.5 x 4ft, assuming a 4ft wide shear) strips in minutes. Just set the backstop, push the metal to it, step, push, step, push, step, ad nauseum. Then adjust the backstop to the desired length of the plates, feed the strips in and push, step, push, step, push, step, etc., until the strip is gone. Repeat. Now you have loads of rectangular plates.
A simple 45 degree jig would allow the same operation to cut bottom corners of the plates off to make the "home plate" shape. Step, turn, step and a plate is done.
After that I guess it's a matter of finishing the corners and edges (grinder?) and punching the holes. Very little deburring would be needed for the edges if any because of the consistency of the cuts.
(As a side note, there is a neat little tool that is used by machinists to deburr small holes. I don't know what it's called but it's made from hard square barstock of some sort, has a handle that the bar is inserted into, the bar turns 90 degrees to the handle where it comes out of it, goes a length of about 3/4 of an inch, then turns 90 d down again for about an inch. Put the bar in the hole, move handle in a circular motion, and voila! the hole is deburred quickly.)
Any good sheet metal shop should be already set up to handle this sort of task and could show anyone (for a price?
) how to set it up. The big cost is the shear. However it would be invaluable for coats of plates, lamellar and other simple gutter-type armor. Even for sizing down a piece to be shaped other than square or rectangular. It's simply bulk cutting made easy with no power. A lot more cutting in a lot less time than with a beverly as long as you're going for straight cuts only.
If I had one, I'd be pumping out all sizes and (geometric) shapes of plates for anyone that wanted them.
Angus (Matt itrw)
(i ought to keep my hands tied behind my back)
Also Truehearth just sent out an awsome suit with brass trim, and makes me feel small. He's getting better every year. (he should be posting pics of it on his site soon)
The camera works again! This is the armor completed to this point. I have some final leather work and decorations to do then I'll post more pics!
