Making Knees

  • Knees08
    Gently planishing the surface will help the piece accept it's new form, smooth the surface, and hammer-harden the product.
  • Knees01
    Patterns for this are easy. Wrap a piece of pattern paper around your knee and draw the shape a little larger than you expect.
  • Knees02
    Start dishing the cop in a shallow wooden (soft) dishing tool, using a heavy rawhide mallet.
  • Knees03
    Switch to a metal (hard) dishing tool for more aggressive dishing.
  • Knees05
    Be careful with aggressive dishing - it's faster but can easily warp the piece.
  • Knees04
    Larger wrinkles like this one at top right edge need to be flattened as you go.
  • Knees06
    Both pieces started and one of the articulating lames has been cut out too.
  • Knees07
    Fitting the cop to the wearer's knee, allowing some room for padding.
  • Knees08
    Gently planishing the surface will help the piece accept it's new form, smooth the surface, and hammer-harden the product.
  • Knees01
    Patterns for this are easy. Wrap a piece of pattern paper around your knee and draw the shape a little larger than you expect.

I use large graph paper to make patterns. (Find them at art stores/departments in artist’s size tablets.) The lines make it easier to maintain symmetry while developing your pattern from paper.

These will be wingless (fanless) knees. Popular with archers, and thus often called “archers knees”. Design is centered around a main plate called a knee cop. (A knee cap is part of your leg. A knee cop is the armor that protects your knee.)

While dishing the knee cop is the most visually obvious part of this project, it is important to note that the final shape does not represent 180 degrees of coverage. Slightly less than 180 around the knee is important for proper articulation. If the knee cop was truly 180, articulation would easily over-extend, causing gaps between the pieces, through which weapons would slip. As with all articulating armor, the pieces must not gap when fully extended/articulated, but should find stop points – limits that stop the armor from opening and closing too far. This must be by design, and the craftsman is responsible for doing this well.

A properly articulated joint, like a knee or elbow, will articulate smoothly and not bind, gap, or feel tight. Any resistance will hinder the wearer’s movements.