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The Links
Chainmaile Main Page
Basics | Patterns
The links are the round rings of wire which make up chainmail. The strength of
a piece of maile will depend on a number of factors. Here we cover wire size, link size
and material. Later on we will go into pattern strength a bit more.
Link Size
For use in jewelry and fashions we often use 16 guage wire. If you want your piece to
stand up reasonably well in battle you'll probably need 14ga. or better, depending on the
type of battle. I realize that many chainmail makers use much larger links, but for
strength and quality we don't recommend going over 5/16" inside diameter (ID) for 16
ga. or 3/8" for 14 ga. wire. If you expect a piece to be under stress, using a larger
size ID will usually require that you also go up in wire size.
When choosing your wire and ID size remember that:
 | A piece of 14 ga. 5/16" ID is much heavier than
that of a piece of 16ga. in the same ID. |
| Smaller link size greatly increases the time
and materials involved. It also increases the weight
of the piece. On the other hand, we've found that the
tighter the pattern, the more comfortable the piece
is likely to be. |
| Some patterns can't be done in some link sizes. For instance,
16ga 1/4" ID rings are a very nice combination, but if you
can even put them into a 6 in 1 European pattern, it can be
impossible to fit links into rows further on. |
Materials
The least expensive and easiest to find wire would probably be galvanized steel. They
can often be found at a store like Agway or Home Depot, also look for fencing wire at farm
supply stores.
| Galvanized steel will darken over time. Low quality also
often flakes or gets patches of a white, powdery build-up
on it. This powder is corrosion on the zinc coating and
the metal can be processed so to be protected from this.
Corrosion-resistant wire can be found through
wire manufacturers and distributers. Rumors that galvanized
steel is dangerous have arisen because of the fact that it
releases dangerous fumes when burned
(*burning* metal is not easily accomplished under normal use).
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| Some people use Regular steel for more authentic armor.
However, this metal is relatively soft and will rust so I don't
recommend it for use in jewelry and costuming. Wire which needs to be bought from
welding supply shops,
manufacturers and distributers may mean having to output
alot of money so that you can reach the minimum order
required. Check the yellow pages or business to business
directory to find local suppliers.
The Thomas Register is an
excellent resource if you've got the time to make alot of phone calls.
When calling, remember that these companies are used to
dealing with large businesses.
 | Nickel-plate is bright and shiny. It often strengthens
a soft metal. |
| Aluminum is often both dull and very soft. However,
certain alloys are made which are excellent for chainmail
applications. The bright aluminum wire that we use is 5356
alloy welding wire. This alloy is almost as strong as steel for
the size. This alloy is perfect for fashions and jewelry. It is light
enough to be comfortable, yet is almost as strong as steel. It's
shiny surface barely dulls with wear. Contrary to popular belief,
this material runs much more expensive (by the foot, as well as weight)
than the galvanized steel. |
| The samples of Nickel silver which I've tried seem to leave tiny
burrs and sharp edges when it was cut. This is probably due to
the hardness of the metal, and it is likely that there is some alloy
out there which wouldn't have this problem. Currently, I've decided
to not bother with it, therefore, there isn't much more I can say about it. |
| For gold-toned wire, I prefer Brass. When using this metal remember
to compensate for the softness and additional weight. Be aware that
some brass may tarnish a great deal so a good alloy is to be desired.
Stainless steel neither rusts nor discolors easily, but good stainless
can be fairly expensive. Stainless comes in many different alloys and
such variables as hardness and chromium content depends on that.
I'm not an expert on metals, so I'll leave the research on various alloys
up to you.
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Chainmaile Main Page
Basics | Patterns
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