A Comprehensive Guide to Finding, Selecting, and Wearing Replica Chainmail

Introduction

Chainmail, with its intricate weave of metal rings, has long captured the imagination of cosplayers and roleplaying enthusiasts. Its allure lies in its historical significance, aesthetic appeal, and the sense of authenticity it brings to any fantasy or sci-fi costume. However, finding the right replica chainmail involves navigating a maze of materials, vendors, and characteristics. This article will guide you through the process, ensuring that your chainmail not only looks great but also meets your practical needs.

The Challenges of Different Materials

 

Aluminum

Pros:

• Lightweight and easy to wear for long durations.
• Resistant to rust and corrosion.

Cons:

• Less durable compared to other metals.
• Can appear less authentic due to its lighter weight.

 

EVA Foam

Pros:

• Extremely lightweight and comfortable.
• Easy to work with and modify.

Cons:

• Less authentic in appearance.
• Not as durable, especially for high-movement activities.

Key Characteristics of Good Chainmail

Historical Accuracy

For historical reenactors or those seeking authenticity, iron or steel chainmail is ideal. Look for patterns and weaving techniques that match historical designs.

Appearance

The aesthetic appeal is crucial. Ensure the chainmail has a consistent weave and uniform ring size. The finish should match the desired look, whether it’s a polished knightly sheen or a darkened, battle-worn appearance.

Maintainability

Iron and steel require regular maintenance to prevent rust. Aluminum and titanium are lower maintenance options. Consider how much time and effort you’re willing to invest in upkeep.

Consistency

High-quality chainmail will have a uniform pattern with no missing rings or gaps. Check reviews and product images to ensure consistency.

Usability

Consider the weight and flexibility of the chainmail. It should allow for a full range of movement and be comfortable enough to wear for the duration of your event.

Durability

The material and construction quality directly impact durability. Choose materials like steel or titanium for high durability, especially if you plan on wearing the chainmail frequently or during active performances.

Selecting a Replica Chainmail Suit

Availability and Cost

High-quality chainmail can range from affordable to very expensive, depending on the material and craftsmanship. Evaluate your budget and the importance of authenticity and durability in your decision.

Evaluating Vendors

Here’s a comparison of major chainmail vendors based on key characteristics:

Vendor	Material Options	Price Range	Historical Accuracy	Appearance	Durability	Body Coverage	Delivery Time
Burgschneider	Iron, Steel, Aluminum	Moderate	High	High	High	Full	Moderate
Novica	Aluminum, Resin	Moderate	Moderate	High	Moderate	Partial	Moderate
RingMesh	Stainless Steel	High	Moderate	High	High	Full	Fast
Propsmaker	Resin	Low to Moderate	Low	High	Low to Moderate	Partial	Fast
InfinityArmory	Iron, Steel, Aluminum	Moderate to High	High	High	High	Full	Moderate
Knights Templar	Iron, Steel	High	High	High	High	Full	Moderate
Armor Venue	Iron, Steel, Aluminum	Moderate	High	High	High	Full	Moderate
Chainmail Joe	Aluminum, Titanium	Low to High	Moderate	High	Moderate to High	Partial to Full	Moderate
India Makers	Iron, Steel, Aluminum	Low to Moderate	Varies	Varies	Varies	Partial to Full	Slow
Etsy Sellers	Various	Varies	Varies	Varies	Varies	Varies	Varies

Tips for Selection

• Research: Read reviews and check customer photos. Vendor reputations are built on quality and reliability.
• Try Before You Buy: If possible, try on chainmail at conventions or local reenactment groups to get a feel for different materials and weights.
• Custom Orders: Many vendors offer custom sizing and designs. Ensure your measurements are accurate for the best fit.

Wearing and Maintaining Replica Chainmail

Comfort and Fit

Chainmail should fit snugly but not restrict movement. Wearing padded garments underneath can increase comfort and prevent chafing. Ensure your chainmail covers the necessary areas, such as torso, arms, and legs, for your character or role.

Comfort Tips

• Padding: Always wear a padded garment (gambeson) underneath chainmail to prevent chafing and distribute weight evenly.
• Weight Distribution: Balance the weight by using additional supports like belts and straps to alleviate pressure from shoulders. Remember that lightweight chainmail can actually rise instead of pulling down. 
• Break-in Period: Wear your chainmail around the house to get used to its weight and movement restrictions before attending an event.

Movement and Flexibility

Practice moving in your chainmail before wearing it to an event. Perform activities such as walking, running, and bending to ensure it doesn’t impede your movements.

• Practice Moves: Engage in typical actions like walking, running, and bending in your chainmail to ensure flexibility.
• Layering: Combine chainmail with other costume elements like tabards, tunics, and capes for a complete look.
• Resin and EVA: Softer materials like resin and EVA can more prone to wear and damage in movement. Check for any regular contact points and consider additional barriers or padding between chainmail and other objects, such as a tabard between your armor and money pouch.

Maintenance Tips

• Cleaning: Regularly clean your chainmail to prevent rust. For iron and steel, use oil or rust inhibitors. Aluminum and titanium need less maintenance but should still be cleaned to maintain appearance. Resin and EVA should be dusted or spot cleaned as necessary.
• Storage: Store chainmail in a dry place. Consider hanging it to prevent links from tangling. Cover with plastic or microfiber material to reduce dust.
• Repairs: Learn basic chainmail repair techniques. Missing or damaged rings can usually be replaced with pliers and spare rings. Resin and EVA rings (or loops in some examples) can be glued and repainted. Make sure you use glues and finishes with will not damage the resin or EVA. 

Advanced Tips for Cosplayers

Layering for Realism: For a more realistic look, layer your chainmail with other medieval or fantasy garments. Combine it with leather armor, tabards, and cloaks to enhance your costume.

Embellishments: Add unique elements like brass rings or fabric inlays to personalize your chainmail.

Adding Embellishments: Personalize your chainmail with decorative elements like brass rings, fabric inlays, or painted details. This can make your costume unique and visually striking.

Lightweight Alternatives: For longer events, consider wearing lightweight alternatives such as aluminum or even fabric chainmail for comfort, while saving the heavy iron or steel for shorter appearances or photo sessions.

Vendor Comparison

To further assist you in selecting the best vendor for your replica chainmail needs, here are more in-depth details about some of the major suppliers:

Burgschneider

• Materials: Offers a variety of materials including iron, steel, and aluminum.
• Historical Accuracy: High. Known for producing historically accurate pieces.
• Appearance: Excellent finish and detail.
• Durability: High, especially with proper maintenance.
• Body Coverage: Full suits available.
• Delivery Time: Moderate, usually within a few weeks.
• Price Range: Moderate, providing good value for the quality.
• Current prices for a full sleeve hauberk range from $370 for iron, to $1800 for titanium

Novica

• Materials: Primarily aluminum and resin.
• Historical Accuracy: Moderate. Focuses more on visual appeal.
• Appearance: High-quality visual representation.
• Durability: Moderate, suitable for cosplay but not heavy combat.
• Body Coverage: Often partial suits or accessories.
• Delivery Time: Moderate.
• Price Range: Moderate, suitable for those looking for a balance between cost and appearance.
• Availability can vary significantly, as goods are handcrafted and subject to artisan participation.

RingMesh

• Materials: Specializes in stainless steel.
• Historical Accuracy: Moderate.
• The company makes chainmail for everyday protection scenarios, so historical models are heavily influenced by modern designs.
• Appearance: Very sleek and polished.
• Durability: High due to the use of titanium in steel alloys.
• Body Coverage: Full suits and accessories.
• Delivery Time: Fast, often ships within days.
• Price Range: High, reflecting the premium materials used.
• Current prices range from $342 for a vest to $451 for a full sleeve hauberk

Propsmaker

• Materials: Resin - 3D models for printing.
• Historical Accuracy: Moderate.
• Appearance: High, especially for lightweight needs.
• Durability: Low to moderate, best for lightweight cosplay. Very dependent on resin choices, some may be more durable than others.
• Body Coverage: Variable, typically used for decorative purposes. 
• Coverage is controlled by the maker, as final assembly is made by the cosplayer.
• Delivery Time: Fast.
• Price Range: Low to moderate, good for budget-conscious cosplayers.

InfinityArmory

• Materials: Iron, steel, aluminum, titanium.
• Historical Accuracy: High.
• Appearance: Detailed and polished.
• Durability: High.
• Body Coverage: Full suits available. 
• Delivery Time: Moderate.
• Price Range: Moderate to high, depending on material and customization.
• Current prices range from $110 for an aluminum hauberk to $250 for a mild steel hauberk, $270 for a brass hauberk, and $720 for titanium. 
• Size will influence cost by as much as 1.6x for XXL.

Knights Templar

• Materials: Iron, steel.
• Historical Accuracy: High.
• Appearance: Very authentic.
• Durability: High.
• Body Coverage: Full suits.
• Delivery Time: Moderate.
• Price Range: High, aimed at serious reenactors and collectors.

NOTE: Actual sales are through Toledo Sword. Currently not selling chainmail, may make available in future.

Armor Venue

• Materials: Iron, steel, aluminum.
• Historical Accuracy: High.
• Appearance: High-quality finish.
• Durability: High.
• Body Coverage: Full suits.
• Delivery Time: Moderate.
• Price Range: Moderate, good balance of cost and quality.
• Butted-rings - range from $150 for iron
• Rived-rings - range from $260 for aluminum, $845 for mild steel, and $1755 for titanium 

Chainmail Joe

• Materials: Aluminum.
• Historical Accuracy: Moderate.
• Appearance: High-quality, polished finish.
• Durability: Moderate to high.
• Body Coverage: Partial to full suits. DIY Chainmail kit.
• Delivery Time: Moderate.
• Price Range: Low to high, offering a wide range of products.
• Kits range from $99 to $109 for 23K rings, may require multiple kits for various options.
• Average chain mail hauberk requires approximately 20K rings.

India Makers

• Materials: Iron, steel, aluminum.
• Historical Accuracy: Varies greatly.
• Appearance: Varies; can range from basic to highly detailed.
• Durability: Varies; generally lower quality control.
• Body Coverage: Partial to full suits.
• Delivery Time: Slow.
• Price Range: Low to moderate, often very affordable but quality can be inconsistent.

Etsy Sellers

• Materials: Various, including unique and custom options.
• Historical Accuracy: Varies widely.
• Appearance: Can be highly unique and custom.
• Durability: Varies.
• Body Coverage: Varies, often partial or custom pieces.
• Delivery Time: Varies, dependent on seller.
• Price Range: Varies widely, from budget to premium.

Chainmail Ring Closures: Tips and Considerations

When it comes to replica chainmail, the type of ring closure is a crucial factor that impacts the authenticity, cost, quality, and maintainability of your chainmail. Here's a detailed look at the different types of closures and what to consider when selecting your chainmail.

Types of Ring Closures

1. Butted Rings
• Description: The ends of the rings are simply butted against each other.
• Materials: Commonly used with aluminum and mild steel.
• Authenticity: Less historically accurate, as most historical chainmail used riveted or welded rings.
• Cost: Lower cost due to simpler manufacturing.
• Quality: Lower strength; rings can come apart more easily.
• Maintainability: Easier to repair, as rings can be replaced without special tools.
• Vendors: Many vendors offer butted rings, including Chainmail Joe and various Etsy sellers.
2. Riveted Rings
• Description: The ends of the rings are overlapped and riveted together.
• Materials: Typically used with steel.
• Authenticity: High historical accuracy; most medieval chainmail used riveted rings.
• Cost: Higher cost due to more complex manufacturing.
• Quality: Higher strength and durability.
• Maintainability: More difficult to repair; requires rivets and tools.
• Vendors: Burgschneider, Knights Templar, and Armor Venue often provide riveted chainmail.
3. Welded Rings
• Description: The ends of the rings are welded together.
• Materials: Commonly used with titanium and stainless steel.
• Authenticity: Moderate historical accuracy; welding was less common historically.
• Cost: Higher cost due to welding process.
• Quality: Extremely strong and durable.
• Maintainability: Difficult to repair; welding tools required.
• Vendors: RingMesh and some high-end Etsy sellers offer welded chainmail.
4. Flat Rings
• Description: Rings are flattened and may be either butted or riveted.
• Materials: Typically steel or iron.
• Authenticity: Historically accurate, as flat rings were used in some medieval armors.
• Cost: Moderate to high, depending on the closure method.
• Quality: High strength; riveted flat rings are especially durable.
• Maintainability: Riveted flat rings are more challenging to repair.
• Vendors: Some specialized vendors, such as InfinityArmory, provide flat rings.

Considerations for Selecting Ring Closures

Authenticity:

• Riveted rings are the most historically accurate and provide a more authentic look and feel.
• Butted rings, while less accurate, can still provide a good visual representation for cosplay.

Cost:

• Butted rings are generally the least expensive, making them a good choice for budget-conscious cosplayers.
• Riveted and welded rings are more expensive but offer better durability and authenticity.

Quality:

• Riveted and welded rings provide superior strength and longevity, suitable for heavy use and combat reenactments.
• Butted rings are less durable and may require frequent repairs if used extensively.

Maintainability:

• Butted rings are easier to repair, as you only need pliers to open and close the rings.
• Riveted rings require more specialized tools and skills for maintenance.
• Welded rings are the most difficult to repair, often requiring professional help.

Vendor Offerings:

• Burgschneider: Offers high-quality riveted and flat ring chainmail, ideal for historical reenactments.
• Novica: Focuses more on visual appeal with butted rings, suitable for lightweight cosplay.
• RingMesh: Specializes in welded titanium and aluminum rings, providing high durability.
• Propsmaker: Uses butted rings for their EVA foam and aluminum chainmail, offering lightweight options.
• InfinityArmory: Provides both riveted and flat ring chainmail, balancing authenticity and quality.
• Knights Templar: Known for their authentic riveted chainmail, suitable for serious reenactors.
• Armor Venue: Offers a range of ring closures, including riveted and butted rings.
• Chainmail Joe: Supplies a variety of butted and riveted rings, catering to different needs and budgets.
• India Makers: Often provide butted ring chainmail at lower costs, but quality can vary.
• Etsy Sellers: Wide variety of ring closures available, with many custom and unique options.

Advanced Tips for Chainmail Enthusiasts

• Mix and Match: Consider mixing different ring closures for different parts of your armor to balance cost and durability.
• Custom Repairs: Learn basic riveting techniques if you opt for riveted chainmail, to handle minor repairs yourself.
• Aging and Weathering: For a more authentic look, age your chainmail by applying a patina to the rings, giving them a more worn appearance.

With this comprehensive guide, you can make informed decisions about the type of ring closures that best suit your cosplay or reenactment needs, ensuring you achieve the perfect balance of authenticity, durability, and cost. Happy chainmail crafting!

 

Conclusion

Replica chainmail can significantly enhance the authenticity and visual appeal of your cosplay or reenactment. By carefully selecting the right material and vendor, and maintaining your chainmail properly, you can ensure that your costume not only looks impressive but also lasts for many events. Whether you’re aiming for historical accuracy or simply want to add a realistic touch to your fantasy character, the right chainmail can make all the difference.

Exclusive Tip: To quickly fix rust spots on iron or steel chainmail, mix vinegar and baking soda into a paste, apply it to the rust, let it sit for a few minutes, then scrub with a brush. Rinse and dry thoroughly before applying a light coat of oil to protect the metal.

With these tips and insights, you’ll be well-equipped to make informed decisions about your chainmail, ensuring you look and feel like a true hero in your next adventure. Happy cosplaying and may your chainmail shine bright in every quest and battle!

Note: vendor information may change at any time, including prices, materials, construction, and availability.