Connor O's Senior Project Blog

Project Title: Ars Faciendae Armae Romae: The Art of Making Roman Armor
BASIS Advisor: Thomas McMath
Internship Location: Allenson Armory
Onsite Mentor: David Goodman, Owner, Iron Rhino Forge



Project Abstract

For my 16th birthday, I asked my mom to give me a lesson at a blacksmith’s shop. I had the opportunity to tour his shop beforehand and in my first lesson, I forged a simple J-hook. At that point my interest mainly pertained to swords, knives, hammers, and tools. I had heard from various people within the blacksmithing community how armoring was much different than traditional blacksmithing, requiring a completely different set of tools and techniques. For my 17th birthday, I was gifted Mark Aspery’s Mastering the Fundamentals of Leaf-Work and became fixated on the idea of creating decorative leaves using “Repoussé” techniques. Soon thereafter I realized that these skills were nearly identical, if not harder, than actual armoring. In the coming weeks, I plan to investigate lesser-known smithing techniques, such as raising, forming, and creasing, which are more practical on larger projects than repoussé. I will create the extensive number of different stakes and hammers required to do so, and then I will culminate my research by recreating a Roman Imperial Gallic “G” Helmet. To do so, I will be working closely with David Goodman at Iron Rhino Forge, who is a humble expert in the field of traditional ironmongering and will provide insight into the many different techniques required. I will also be communicating extensively with a colleague of Mr. McMath from the University of Arizona, who specializes in Roman armor’s specifications through his archaeological experience. This colleague’s experience in metallurgy will ensure that I do not just recreate a helmet which resembles my desired product, but one that is identical to historical examples of the Roman Imperial Gallic “G” Helmet.

    My Posts:

  • 4/22/24: The End

    As I made last week's post, a certain realization came to me that I was much closer to finishing the helmet than I anticipated. In just a few hours, I managed to get the whole thing assembled and officially complete:   This week I plan on doing more of a professional photoshoot of the helmet... Read More

  • 4/15/24: The Assembly

    The helmet has technically been made, all that has to be done at this point is actually assemble it together. The next few days I expect to be doing a lot of drilling and riveting to properly attach all the pieces to the helmet. If all goes well, I could have this finished in the... Read More

  • 4/8/24: Dremel, Dremel, Dremel

    This week seems more unproductive than the last few, but nonetheless time continues to be poured into the helmet. The bowl of the helmet is officially polished and ready to be assembled, while the backside and rear still need more sanding. You can see that the front of the helmet has a very smooth look... Read More

  • 4/1/24: One Must Imagine Sisyphus Sanding

    Now that the basic shape of the helmet is done, the only sections I need to do are the furniture that a crest would be attached to, the carry handle at the rear of the helmet, and the brass trim around the edges of the helmet. For guidance on the latter, I consulted Michael Allenson... Read More

  • 3/25/24: Chiseling and Chasing

    This past week has been extremely productive, as I have completed forging the entire "base" of the helmet, composed of the bowl, neckpiece, and cheek guards. I started off on the latter, which proved to be extremely easy with how much practice I had with Michael on raising, and thanks to the repousse section in... Read More

  • 3/17/24: No Rest for the Wicked

    This week, while I am on Spring Break, I have decided to do a great deal of research into the project. While many questions remain unanswered, just as many have been explained. David Sim's book Roman Imperial Armor, recommended to me by Mr. McMath's colleague, describes that under the emperor Hadrian, the total number of soldiers... Read More

  • 3/4/24: A Brief Respite

    This past week, I completely restarted the project, using slightly thinner steel (18 gauge/1.2mm instead of 12gauge/2.6mm) as well as a more modern approach. Instead of brute forcing the material into the hemispherical shape of a helmet, I decided to cut individual triangles out of the sheet metal and weld them together. While this process... Read More

  • 2/26/24 Cutting Corners, Literally.

    My progress last week was cut short due to sickness. That being said, I noticed myself starting to get way behind schedule. So, I resorted to a little saying my dad taught me: "If you ain't cheating, you ain't trying." This was the status of the helmet a week ago -- not very helmet-like, but... Read More

  • 2/20/24: A Change in Course: Raising

    As with all projects, this one started with a trip to the metal supply store: On the far left of the image, you can see the "remnants" section -- that contains the cutoffs leftover from when big contractors, such as welding companies, bulk order specific sizes, or when careless customers and employees bend or blemish... Read More

  • 2/12/24. All Armor is Divided… into Three Techniques?

    About two years ago, I started my own blacksmithing business, selling knives, hammers, and just about anything else I could imagine. Now, as a senior, I have more than enough free time to run the business, so instead of looking to make more money, I want to have fun. And to have fun, I'm going... Read More