Issue 38

This issue was not too difficult. The only part included was a large sheet of chainmail. I also used the parts from issue 37 and one other piece from issue 36. However, as I had no use for that part until now I just kept it in my toolbox.

For this issue I had to carefully extract sections from the chainmail to shape it, and then attach the parts at the top and bottom. As you can tell this process did not take a long time to complete. I believe this was the fastest I have assembled any issue to date. The next issue appears to be the more demanding one I have been expecting.

Issue 37

This issue was also not overly difficult. While working I started to feel an overwhelming sense of déjà vu, then I realized that I completed the mirror opposite of this part ten issues ago. I must now face the truth of my actions and admit that I have begun to assemble the other arm.

Unfortunately there is not much else to say about this part. I had to open and then close several tiny links of chainmail join these armoured pieces together. It was not overly complex or demanding work and that usually means a much more complicated issue is coming soon.

Issue 36

This issue was almost exactly like the the last issue. I made two more strips of armoured plates and then I attached them. There is nothing else to say about it. Next time I will be starting work on the armoured sections of other sleeve. Although it's a new part, I expect it to be the same as my completed one.

Also, astute readers may note a slight delay in getting this issue finished. It had nothing to do with the difficulty or technical demands of the work. Usually around this time of year I have less free time. However, I am excited about the progress I have made these last few months, and I am not ready to stop again.

Progress may be slow, but it continues...

Issue 35

This issue is the start of the next part of the armour, the upper leg guards. I found that after completing the plate sets that were attached to the body,  working with these is far easier. The main action of this issue was to create two strips of 11 corrugated plates then to attach them to the silk backing. Fortunately all the points where I had to punch through the backing were already indicated with tiny silver marks, greatly simplifying the process. This is the start of two identical pieces, each with six strips attached, for a total of 132 tiny corrugated plates.

There is not much else to say about this one, and I think I'll have even less to say about the next issue.

Issue 34

I assumed, when starting this issue, that things would proceed smoothly and simply. The only parts included were four very small pieces to make two opening joints and 105cm of leather cord. I don't think any previous issue has contained so few parts. Even issue 27, although it had almost no work, still included a handful of pieces. This issues was going to be the antithesis to that one.

It started rather tame, cutting the cord into 3 pairs of smaller segments. However, that would be the only easy part of this entire issue. Next, I did the finger and thumb loop attachments. This involved aligning the holes in the metal pates with the corresponding holes in the leather and silk layers, and then pushing the leather cord through each one three times. This process would be a reoccurring theme for the entire issue, forcing more and more leather cord through progressively smaller holes. Although was not impossible it was very exact, and if things were not done perfectly, they were not going to work at all. Had the designers of the armour increased the diameter of the holes by about 0.5mm I don't think any of the the visual or structural effects would be diminished, but it would have made the process so much easier by adding a tiny bit of much needed 'wiggle room'.

Eventually I completed the process. I am particularly pleased with how the knots on the back of the hand section turned out. Although I refer to them as knots, the cord is not actually tied. It is only twisted and held in place with glue. This issue also completes this piece of the armour, so now I have my second finished part. In the next issue I am returning to my classic armour building techniques. I'll be cutting and gluing silk string and then lacing together some tiny plates. Again...

Issue 33

This was a complex issue, and one that required more unique different steps then I have seen in a long time.

First I had to assemble the wrist strap. This part is like several similar pieces I made when assembling the plates that are attached to the main body. The second step involved the most labour intensive action of the issue, attaching the blue lining to the inside edge of the sleeve. This required gluing the lining to the leather edge and following almost the entire perimeter with close hand stitching. Several times I used a little too much glue and attempting to push a needle though became quite difficult. At these points I used the craft plies to better hold and push the needle. It took a long time, longer then I was expecting, because I tend to be very precise with the stitching. Third I had to attach the leather section over the lining in the hand area. This was also done by gluing it in place first, then stitching.

For the third step, after the stitching was completed, I used some new and old tools. A new punch, included in this issue, and my old hammer to make a series of holes along the edges for a cord to bind the two together. When starting this project the series guide included a list of (...and as I would discover, it's only a partial list of...) the tools and equipment needed to complete the project. On that list was a hammer and I spent a lot of time carefully searching for just the right one. However, until now it's just been sitting next to my toolbox unused.  Also for this issue bought a very hard rubber plate to strike the punch into. I found this was quite helpful, as I did not damage my work surface, or the punch itself.

The fourth, and final, step of assembling this issue involved threading the cord in the newly punched holes. This often felt like it was just beyond my ability. It was not a complex process, but I still made several mistakes. I had to reverse and try again several times before I finally got it right. Compounding the problem was the end of the cord was just encased in masking tape and that had a tendency to come off as I was working. I had to re-attach a tape tip several times to complete the process.

Now that this entire sleeve is nearly finished I'm starting to get excited about the future. Despite all these difficulties I feel that I have learned a great deal about the assembling of sleeves and I'm excited to get another chance to apply what I have learned when I assemble the other sleeve. What new mistakes will I make? Only time will tell...

What is the final piece of the armour?

Issue 55 is going to be the last one for this project. For a while I have been wondering what parts are going to be in that final issue. Today I am working on issue 33. In my to-do pile I have up to the current issue, 41. Furthermore, on the website I can see previews of upcoming issues, up to 44. However, the contents of the remaining issues, 45 to 55, are unknown.

So what parts are in those last issues? I know the upcoming issues have some parts for the other sleeve and the upper-thigh guards. However, I have not seen an issue yet that has any pieces of the shin guards. Those must still be coming in 45+. I don't know how many it will take to finish each shin guard, or what order the parts will come, but I don't think that really matters. What I am wondering about is the last issue, what will be in it? What final part, or parts, will it contain to complete the armour?

I think it will be the golden "moon" crescent that attaches to the helmet. It is the most identifying signature piece of the whole armour. Images of Date Masamune always feature the black armour topped with a golden crescent. I think it would be quite fitting for the final piece of this armour project to be that signature crescent, and because it was not in the first few issues they are probably saving it for the last.

Issue 32

This issue was not as complex as I thought, although one step was quite time consuming. I have mentioned that one part was incorrectly manufactured in this issue. To correct this problem I called the company and they sent me a replacement part within 72 hours, at no cost. However, upon further examination this particular part is unneeded until issue 33.

So about this issue. The main construction involved attaching the metal sections to the silk of the sleeve. First I stitched the top and bottom parts. I found this to be tricky. I had to reattempt the thumb section twice as I was not happy with how it was progressing. Next, I had to carefully stitch down some of the links in the chainmail sections. This part was less technically demanding, but finding and attaching the correct rings took a lot longer then I expected. I believe working with black thread on black silk and counting black rings did nothing to alleviate the difficulty. However, the finished piece did turn out correct.

The next issue looks like a long and complex one, the instructions cover six full pages and I bought 2 new tools to to complete the work.  I'll also finally get an excuse to use my hammer.

From 17 to 30, a progress check

In this blog when I finish a piece of the armour I just take a photo of that part. However, I have not shown any full progress shots since issue 17. So today I took my armour outside and I took a few shots of the main body, mask, and helmet. I still plan to keep detailing the progress made in each issue, this is just a chance to show all that I have done so far.

Issue 31

This issue only had just a few parts, so it it did not take very long to finish. I added the hand and thumb guard to the chainmail and armoured sections of the sleeve. It was fortunate that I did not throw out the extra chainmail that I removed from the parts from issue 29, as I needed to use some of it to complete this issue. Although I believe somewhere in the instructions it said to keep it, I can not be sure because I am unable to fully understand them. Fortunately,  I do tend to keep the scraps and extras anyway, so I had enough extra links in my toolbox.

With this issue the armoured sections of the sleeve is complete. Next, I will begin to sew them to a silk and leather sleeve. I examined some of the parts for the next issue and I suspect one of them, the lining,  may have been cut incorrectly. This could result in a delay in completing that issue as I attempt to contact the company and get a replacement part.

Issue 30

This issue is the final time I will be making armoured plates. The parts in this issue made a full set of six plates, and that's it. Just six metal plates, six backings, about 255cm of blue silk thread, 70cm of gold, and two tiny metal pieces to make a removable joint. Those are required because this set is attached to both the back and side armour.

I have now finished making all the armoured plates for this project. In total there are eleven sets of six plates, 66 plates in total, that I have joined together. They add a lot of weight to the armour, but the whole effect also really looks good. With the golden thread outlining the edges of each set, the overall impression is quite striking.

The main body of the armour is almost complete and the rest of the details to finish, except for the standard attachment, are all quite minor. For the next few issues I'll be working on the sleeves.

Issue 29

This issue felt more like a typical issue to be working on. I made some plates, then I joined them to the ones from issue 27, and finally I attached the set to the body. I feel a touch of melancholy when considering the next issue, for it shall be the final time I will be working with these plates.

This issue also used the leftover part from issue 27, it's the large piece at the top of the chainmail sleeve. As you can see the main work in this issue was to add more chainmail to the arm guards. I still have to attach a hand and thumb plate, then I'll work on the sleeve itself where this armour will be anchored. For this issue all the chainmail came in one large sheet. I had to count and remove exactly the right rings to give it the correct shape, then open and close all the rings at the top and bottom to join it to the other pieces.

Collecting Issues

When I started this project I knew it would be difficult because I can not read Japanese well. Fortunately most of the instructions are accompanied by excellent photographs and that has been a great help in working on this project. Although the building instructions are only a few pages in what appears to be a very interesting magazine. There are many different sections and chapters chapters of what I assume are: Stories of historical armour building techniques, famous Samurai and notable battles, the life story of Date Masamune, and much more. However, for now all I can do is scrutinize some tiny images on a few pages from each issue. There is much more unexamined content that will just have to wait until my language level improves.

So what do I do with these issues after I have assembled the parts? When starting this project I bought four special binders to keep them. They are hardcover binders with the magazine logo on the cover and an embossed family crest on the back. Each binder holds 14 issues so the complete set of 55, and the series guide, should fit exactly in four.

Issue 28

This issue involved doing something different for me. Unlike the previous 27 issues, this issue stands apart because of it's unique process. There was nothing to glue. Every other issue has involved using at least one of three kinds of glue. The most common is regular white craft glue. A small vial was included in issue one, and I have purchased a larger bottle because I use it so much. The other glues are a fast drying superglue gel for doing detail work, and a thick rubbery type for joining the metal parts together.

This issue also included a new tool, some craft pliers. They are like regular needle nose pliers, but the inside edge has no ridges or teeth, it is smooth. I used them, and my own craft pliers, to open and close many very tiny metal rings to assemble part of the chainmail sleeves.

Issue 27

This issues marks the halfway point for this project. There is not much to talk about in this particular issue, only because there was not much in this one. Of all the issues I have done so far this one is, by far, the simplest. I made three plates. Usually I do that and something else, however the only other part included remains unused for now.

Fortunately, I am well practised at assembling plates. If you ignore time spent waiting for glue to dry there was, at most, only one hours work to finish this issue. Even the instructions were only six steps covering a page and a half.

Issue 26

The mask is now complete. Although I am almost half way into my armour project, I now have my first finished part. There are still 2 more sets of plates to attach to the body of the armour, and the helmet still needs it's straps. Soon I will begin to work on the arms. I am looking forward to that, as it's the start of an all new part of the armour.

Anyway, about this issue. The first part involved finishing and attaching another set of plates. It's not my favourite part of the job, but I have become rather proficient at it. Attaching the neck guard was like a miniature version of attaching the bands to the helmet. As I have already done that, working on this part went smoothly. The helmet was difficult because of the large number of strings I had to work with. The neck guard had less strings, but they were closer together, so it was difficult because of the compact size.

Issue 25

This issue was a continuation of the work done in the previous issue, I was again adding facial hair to the mask. There was also the side job of working on another set of plates, but ultimately it was nothing new. This is the last time that I will have to attach hair to the armour, and despite it being very intensive work, I feel the result is worth the effort as the finished piece looks quite good. The next issue is the neck guard, and that should finish the face mask.

Issue 24

It took a little while longer to get this issue done then I was expecting. This was partly due to a long cold that I still have, and partly due to the rather high level of difficulty in this issue. The main action was putting the beard together. I assembled the mask way back in issues one and two, but since then it has just been sitting in my toolbox. Finally with this issue, and the next few, I should soon finish the mask and neck guard.

The main action of this issue involved tying the hair into bunches of 40-50. I had to count out each pile because I found it very difficult to guess. If I had too many then the bunch would not fit in the hole. However, if I had too few then the bunch would not stay in the hole. It took a long time to separate and count the hairs,  tie them together, thread the bunch through the mask, and then glue it in place. Fortunately, after about the 12th time, I became familiar with the right amount and I could estimate the correct size without counting.

Anyway, after threading and gluing the bunches into the mask I had to give the beard a much needed trim. I think it turned out quite well. The next issue is more of the same as I add a small soul patch, and finally a moustache to the nose guard. Date Masamune was clearly a man of great style.

Issue 23

This one was very simple, yet it took a long time. This issue had very few steps, and each one was not difficult. However, the interval between each step took so long because I had to wait for glue to dry. That is the to secret this, and many other, issues. It takes so long because I must wait for the glue to dry.

That is also why I open the next issue and start that before I finish the current issue. When I make time to work on the armour I don't want to do 15 minutes of work and then spend hours waiting. While I wait for the parts from this issue to dry I will often work on a few parts from the next issue, until invariably I must also wait for that glue to dry too.

I suppose I could keep repeating this process. Every time I must wait, I open another issue and start on that. I would have five or six issues on the go at once, I certainly have enough backlog in my to-do pile. However, I have chosen not to do this for several reasons: I don't have enough room to work on the parts from six simultaneous issues, the parts in later issues often rely on the previous issues to be completed, and ultimately I just don't want to. Making this Samurai Armour is not a race. I'm still about ten issues behind, but I don't mind. I work on this project because it's fun and I do it to relax. The waiting is a part of the process.

So what about this issue? As I stated above, the work was quite easy. I had to make on anther set of plates, as I have done so many times before, and then attach a little silk pad to the left front quarter of the armour. This is a curious piece and I can't really work out what it's function is. I think it has something to do with the way the Samurai would carry his Katana, because this silk sheet covers the side where the Katana would also be kept. I assume it's there to stop the metal guard of the sword from rubbing against the armour. Perhaps this is done to prevent minor damage to both the armour and sword.

Issue 22

This was an interesting, but difficult issue. While I was working on this one I also started working on the next issue too, so I suppose I'll be posting about 23 soon...

About this issue, I first had to finish another set of armoured plates. I thought working on 1/2 scale armour would be easier then working on full sale, but actually I think in some ways it's a little more difficult. For example: to attach a set of armoured plates to the body you need to tie the string so they hang 4cm. If your measurements are not exact for every string then the plates will hang slightly tilted. This will cause one, or more, strings to be pulled and when pulled they look thinner then the others. The difference is only about 1mm, but on the smaller scale that is very obvious.

Well, perhaps it's only obvious to me.

Anyway, the bulk of the work in this issue was creating and installing the lining of the helmet. In this rare case working about 10 issues late has been a benefit. I'm not sure about the process that goes into creating this magazine set, but sometime after the the parts for issue 22 were sealed in plastic, an error was discovered. The leather band that attaches the lining to the helmet was cut the wrong way. The stretch of the material went along the short length, not the long. This would make installing the piece almost impossible.

Fortunately the company caught the error, and a note was also tossed into the magazine warning not to do any instructions after page 8 until you had the replacement piece that would be included in issue 25. I was able to go to my pile and take out the replacement part and finish working on issue 22 without waiting an extra three weeks.

The Mystery of the Box ...

Before I started to make this suit of Samurai armour I had to consider where I was going put it. I thought it would be cool to set it up for the high holidays, but I didn't want to keep it on display all the time. So where can I store it? Should I just toss the armour in an old shopping bag?

Fortunately, the good people at DeAGOSTINI had a solution. They have made a rather nice looking box to keep the armour in.

This box is free, however to get it you must send in a special postcard only found in issue one. On that postcard you must attach 35 tags, one from each each of the first 35 issues of the magazine.

In each magazine, in the bottom corner of one page is a little red number. To receive the box you need to cut out that little number from every issue and glue them to the special postcard. Once you have all 35 you send in the card and they send you the box.

I have not done this yet, as there was no point in starting until I had all the necessary issues. Yesterday issues 34 and 35 were delivered, and included with them was a note saying that I would be receiving the box in a separate shipment by the end of the month.

It would appear that I can get the box without cutting the corners off the pages of my magazines. I assume those who have a subscription get the box automatically. But there is an equal chance that I am mistaken and I will have to send in my completed card.

The expiration date for the postcard is in December, so I have a little time. I think I'll wait a few weeks and see if anything shows up in the mail before I start to cut my issues up.

Issue 21

This issue has been nice and simple, and that has been a welcome change. After completing a few complex issues it was nice to try something new and break out a needle and thread to do some sewing.

It has been a while since I last hand stitched something. Today's part was a small piece, and just the right thing to get me back in practice. I had to close an opening at the bottom where the stuffing was added and there were 5 points where I had to stitch the padding onto the back and shoulder strap sections.

This now means that I can no longer just remove the pins and separate the shoulder pates without severing some tiny thread. 

Issue 20

This was not an extremely complex or difficult issue. However, It did rate high on both accounts. As I mentioned earlier this was the issue that involved a lot of complex measurements and knots in ropes of various, but precise, lengths.

This issue also had me finishing another set of the armoured plates that make a kind of skirt around the waist of the armour. In total there will be eleven such sets, and each has six plates. Assembling these plates has been the only constant action in the first 20 issues, with only 6 issues not including at least one part. Finishing one of these sets does take some time, but I feel that I have become quite proficient at it.

Issue 19

This one was simple and interesting, and I finally had an opportunity to use my punch. However the overall piece is quite small. It's that little pad at the bottom and the ring attachment at the top of the back plate. Eventually there will be a standard mount attached at the back. However, I don't think the flag is a part of this armour set.

The next issue should be like issue 18. Only a few parts, but lots of work.

Issue 18

This was, so far, the most difficult issue I have done. I spent a few nights just slowly threading an endless series of holes. I was worried that I had made some mistake at the start and I'd have to take it all apart and start again. Thankfully it went together right, the first time.

I know the next issue will be much faster. While I was working on this one I took a break by getting the parts ready for the issue 19. It should be a lot simpler then this one. I have looked ahead at all the issues in my to-do stack and I know that soon I'll have a complex issue involving tying knots in ropes at precise measurements and it looks difficult, but not as labour intensive as this issue has been.

Yet, despite the difficulty, I am pleased with the final result. The helmet is really starting to look complete. Although I have yet to do the interior, and mask, and neck guard, I feel that it's coming together all the same.

Issue 17

Well I'm just putting the finishing touches on issue 17.

I feel that completing this issue has been a turning point for the project. So far I have been working on the small pieces, front, sides, etc.. all separately. However with issues 16 and 17 completed I have now assembled the back piece of the armour and, like a good rug, it really ties the whole project together.

Now I can link the 7 main parts of the body and, thanks to the display stand from issues 12 and 13, get a good look at the shape of my armour. I have taken the pile of separate parts and fitted them all together for the first time.

I think it looks damn good, so far...

The Prototype

There was a special display and event in Shinjuku a few months ago and I went to check it out. It included a complete set of the prototype armour from the magazine. I wonder if this is the same set that was used in the TV AD, and for the photos in the magazine? I might be, I don't suppose the company has too many finished sets on hand.

Issues 1 to 16

Sorry I don't have any photos for this part.

When I started the project I did not think to create this blog. That idea only occurred to me after I had started issue 17.

However, if you are hungry for the back story behind those "lost" issues...

After purchasing and examining issue one I decided to try the whole thing. So I signed myself up for a subscription delivery service and then I got to work. In the beginning things went quite well and I built the first 7-8 issues on schedule, but then I became too busy with my work, and my duties for Anime North, so I had to put the project on hold.

I intended to take a few weeks off and return to the project, but those weeks soon became months. While I was not working on the project my subscription kept delivering new issues, so my "to-do" pile was growing quite large.

Finally I had enough waiting and just a few weeks ago I decided to get back into the project. Now I have almost completed up to issue seventeen. As I was working on the latest issue I thought about creating a blog to detail my progress until I finish the project.

From now on I'll try to post something new about each finished issue until the whole set is completed.

TV AD

It's for the armour I'm building

     Check it out.

I never saw this on TV. I found it on the web after I started the project. My armour does not make such a loud "clink" noise. I think you would have to hit the pieces together quite hard to do that, and I don't want to damage anything.

Issue 0

OK. I realize some people reading this may have no idea what I am talking about "Making Samurai Armour?!?"

Let me fill you in. A magazine company, DeAGOSTINI, sells these hobby kit magazines.

Each week a new issue is released with a thin magazine, it's more like a chapter in a book, and a few parts of a much larger project. Each magazine is part of a series, and when the series is finished you have assembled something quite impressive.

Imagine you have subscribed to a 10,000 piece puzzle magazine. Each week you get an issue detailing the history of puzzles, famous puzzles, famous puzzle solvers, etc... and a small box with about 200 pieces of your huge puzzle. If you keep buying every issue of puzzle magazine then after 50 issues you will have all 10 000 pieces.

I am doing a similar project, but instead of making a puzzle I am assembling a 1/2 scale replica of Date Masamune's Samurai Armour.

It started back in late February when I was looking at the "Make Samurai Armour " issue one. I thought I looked quite cool, but was unsure if I really wanted to make it all. The total cost is quite high, and I was unsure if I had the skill to do it right.

However, I bought the first issue to check it out up close. It didn't look so difficult, and the parts were made of real metal! To me the justified the higher cost so I subscribed and got started.

There are 55 issues to complete this project. Currently I have 33. However, many of them are still in the box. As of today I have only assembled up to issue 17.