breather holes and how do you cut them out accurately

[Wyrm]

For my upcoming greathelm I'm interested in a certain design for the breathers. I could possibly awkwardly get them done by a simple drill and jigsaw but I have heard about custom made punches and a tool called a Slitter in the recent post here about breathers. Are there any techniques out there for making breathers?

Wyrm.

[ArtemisGreen]

Use the old drill and file technique. It takes a while, but period armourers didn't have all them new-fangled tools now did they?

[Old Armourer]

Use a jewelers saw; very precise...

[Rainald]

Drill the holes, connect the dots with a jigsaw and clean up with a file.

[Alcyoneus]

Dremel cut off wheels are good for straight lines.

[Halberds]

This is a link to punches:
http://www.mubeamachines.com/page1.htm

They take a very expensive press to make them work.

May I suggest: You make a poster board template of the center holes pattern.
Transfer that pattern to the helm face.

Center punch the holes and drill through with a 1/4" drill. Deburr the holes inside and out.

Some interesting patterns can be made with just holes. Also different sizes of holes will produce some stunning effects.

To drill a helm face; I like to clamp a 2 by 4 to the work bench. Stick it out about 16" so the helm will be supported. Now one can drill through the helm into the wood and the helm does not slip around.

It helps to center punch and pilot drill with a 1/8" first, this will guide the larger drill.

This is a link showing holes in a pattern:
http://users.ev1.net/~rwreid/armour/ima ... Helm4a.JPG
Thanks to Red Dragon Armoury

Hal